Chevrolet 1962 Chevy II Service Manual Download Page 286

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Summary of Contents for 1962 Chevy II

Page 1: ......

Page 2: ...so f ma t e r i a l sc o n t a i n e d h e r e i nh a v eb e e nr e p r i n t e dwi t hp e r mi s s i o n o f Ge n e r a l Mo t o r sC o r p o r a t i o n S e r v i c eOp e r a t i o n s L i c e n s...

Page 3: ...er 4 Door Sedan 6 Passenger 4 Door Station Wagon 2 Seat 4 Door Station Wagon 3 Seat 2 Door Sport Coupe 5 Passenger 2 Door Convertible 5 Passenger 4 Door Sedan 6 Passenger 4 Door Sport Sedan 6 Passenge...

Page 4: ...assenger Reg 2 Door Sedan Pickup 3 Pass Deluxe VEHICLE DIMENSIONS CHEVELLE Pertinent dimensions for the different models are shown in the following chart Model Sedan 197 0 75 0 54 1 115 0 58 0 58 0 2...

Page 5: ...uct failures in any way we are showing below the location of various unit numbers These unit numbers and their prefixes and suffixes are necessary on these papers for various reasons such as accountin...

Page 6: ...ocated on the Upper Left Hand Side of the Dash Panel Chevelle and Camaro Fig 9 Body Style Body Number Trim Type and Paint Combination Located on the Upper Right Hand Part of the Dash Panel Chevy II 1...

Page 7: ...d on Right Rear Vertical Surface of Oil Pan 16 The Turbo Hydra Matic Transmission Serial Number is Located on the Light Blue Plate Location on the Right Side of the Transmission tumbler single bitted...

Page 8: ...mark 3 6 Cuts that fall in second black section mark 4 7 Cuts that fall in the second white section mark 5 After the numbers have been determined and written above the cutting positions the lock cyli...

Page 9: ...12 volts and connect positive to positive and negative to negative Manual Transmission When a push start is necessary turn off all electrical loads such as heater radio and if possible lights turn on...

Page 10: ...ds of the front suspension lower control arms in between the coil springs and the stabilizer bar link bolt fig 23 The chains should be attached to the lower lifting sling bar so that when the vehicle...

Page 11: ...he rear valance panel With the lower bar in this position it is necessary that the bar be spaced down a minimum of 1 5 8 to pre vent damage to the fuel tank This can be accomplished by placing 6 0 sec...

Page 12: ...ce facilities and service stations are now equipped with a type of automotive hoist which must bear upon some part of the frame in order to lift the vehicle In Figures 21 22 28 29 30 the shaded areas...

Page 13: ...GENERAL INFORMATION 0 11 DRIVE ON HOIST BUMPER JACK AT FRAME ATTACHMENT ONLY FLOOR JACK OR HOIST LIFT Fig 29 Vehicle Lifting Points Camaro CHEVROLET CHASSIS SERVICE MANUAL...

Page 14: ...2232 j L j V DRIVE ON HOIST TWO POST HOIST WITH DRIVE ON ADAPTORS FLOOR JACK JACKSTANDS CENTER POST HOIST JACK STANDS Fig 30 Vehicle Lifting Points Corvette Fig 31 Frame Lift Adapters Corvette CHEVROL...

Page 15: ...required During the colder months of the year an oil which will permit easy starting at the lowest atmospheric tempera ture likely to be encountered should be used When the crankcase is drained and r...

Page 16: ...r leaking by pistons and rings and mixing with the oil and by condensation of water on the cylinder walls and crankcase Leakage of fuel or fuel vapors into the oil pan occurs mostly during the warming...

Page 17: ...when extremely low temperatures are encountered for protracted periods during the winter months the SAE 80 viscosity grade may be used Multi Purpose Gear Lubricants Gear lubricants that will satisfact...

Page 18: ...uld not be used Do not mix wheel bearing lubricants Be sure to thoroughly clean bearings and hubs of all old lubricant before repacking The proper adjustment of front wheel bearings is one of the impo...

Page 19: ...Bearing Lubricant Whenever Brakes are serviced CL Chassis Lubricant EO EngineOil AT Automatic Transmission Fluid Type A BF Brake Fluid Fig 32 Lubrication Diagram Chevrolet 1 Front Suspension 2 Steeri...

Page 20: ...sitraction Rear Axle with Special Positraction Rear Axle Lubricant Only AT Automatic Transmission Fluid Type A SL Steering Gear Lubricant BF Hydraulic Brake Fluid 1 Front Suspension 2 Steering Linkage...

Page 21: ...2 000 MILES Whenever Brakes are serviced CL Chassis Lubricant LUBRICATE EVERY 36 000 MILES E O _E n gine Oil BF Brake Fluid Refill Positt Special Lubricant Only Axl with 1 Front Suspension 2 Steering...

Page 22: ...ERVICED CL CHASSIS LUBRICANT CO ENGINE Oil AT AUTOMATIC TRANSMISSION FLUID TYPE A BF BRAKE FLUID Fig 35 Lubricafion Diagram Camaro 1 Front Suspension 2 Steering Linkage 3 Steering Gear 4 Air Cleaner 5...

Page 23: ...Axle 8 Oil Filter 9 Battery 10 Parking Brake 11 Brake Master Cylinder BODY LUBRICATION POINTS CORVETTE Lubricate the following items when possible Hood Latch Mechanism and Hinges Apply light engine o...

Page 24: ...is the temperature door Air from the blower follows parallel paths through the distributor duct with one path passing through the heater core and the other path bypassing the core The temperature doo...

Page 25: ...he Chevy n heater from the blower assem bly With the lever in the half way position this damper will be open to allow airflow into the vehicle Moving the lever further will actuate the three speed LOW...

Page 26: ...r door Air and Defrost Damper Doors Beyond the temperature damper door are the air door and the defroster door both operated through a single bowden cable by the AIR DEF knob The first half of the tra...

Page 27: ...Inside the vehicle remove the case to firewall mounting screws and pull the entire heater and de froster assembly from the firewall remove the Chevrolet defroster cable at this time then remove the a...

Page 28: ...d if low or medium blower speed is inoperative Remove the glove box for access to the unit HEATER HOUSING LOWER RIGHT HAND RETAINER NUT Fig 6 Air Distributor Duct Camaro Fig 7 Access to Blower and Hou...

Page 29: ...aring inserted into the AIR FAN lever slot 4 Connect the blower harness connector and remount the control assembly in the dash CORVETTE Blower Assembly Removal 1 Remove the radiator supply tank from i...

Page 30: ...oved and dis assembled as described under Blower Assembly above Installation 1 With the blower and air inlet assembly in place install the seven attaching stud nuts 2 Replace the blower motor electric...

Page 31: ...radiator supply tank 4 Replace each heater hose to its proper core connection 5 Refill the radiator Defroster Duct Figure 19 illustrates the installation of the Corvette defroster duct Fig 13 Chevy II...

Page 32: ...from its support Fig 16 Heater Hose Routing Chevy II straps and move it out of the way 3 Remove the battery 4 Remove the water supply hoses from the core connections 5 Remove the blower and air inlet...

Page 33: ...h non hardening sealer Attach the core mounting screws 2 Attach the core and plate assembly to the case with the two sheet metal nuts The assembly is ready for installation as described below Heater A...

Page 34: ...HEATER AND AIR CONDITIONING 1A 11 Fig 19 Heater and Defroster Cables Corvette CHEVROLET CHASSIS SERVICE MANUAL...

Page 35: ...HEATER AND AIR CONDITIONING 1A 12 I 20 Heater Hoses Corvette CHEVROLET CHASSIS SERVICE MANUAL...

Page 36: ...al System Chevrolet Chevelle Chevy n Camaro Underhood components that is the compressor con denser and receiver dehydrator are much the same in type location and method of attachment on all of the abo...

Page 37: ...HEATER AND AIR CONDITIONING 1A 14 Fig 21 Four Season System Components Chevrolet Fig 22 Four Season System Components Chevelle CHEVROLET CHASSIS SERVICE MANUAL...

Page 38: ...15 F i g 23 Four Season System Components Camaro EVAPORATOR CORE DEFROSTER OUTLET DEFROSTER DOOR V HEATER OUTLET COOLED AIR OUTLETS Fig 24 Airflow Four Season Chevrolet Camaro Comfortron Chevrolet CH...

Page 39: ...ull control of the Four Season System is obtained through the use of a single control panel fig 26 The control knobs make use of bowden cables to activate the various doors and switches necessary for...

Page 40: ...ash outlets or to the dash outlets only The DEFROSTER lever directs air which is flowing to the heater outlet up to the defroster outlets With the DEFROSTER lever in the OFF position a fixed bleed per...

Page 41: ...s of changes in outside air temperatures Most Comfortron parts are located in the passenger compartment fig 28 Jn Car Sensor The function of the in car sensor is to determine the temperature of the in...

Page 42: ...leration the vacuum supply from the carburetor drops The vacuum tank using a check valve stores vacuum so that under these conditions vacuum will be available for the Comfortron Thermal Vacuum Valve H...

Page 43: ...ed vacuum is applied to the Power Servo Changing the Vacuum Signal to Mechanical Energy The Power Servo controlled by the modulated Trans ducer output vacuum operates the vacuum electrical and mechani...

Page 44: ...erates in conjunction with the heater to provide a complete air conditioning system operating on either outside air recirculated air or a combination of both The cooling unit attaches to the heater di...

Page 45: ...erature control can be maintained This is especially desirable during marginal weather conditions CORVETTE The Corvette Four Season Air Conditioning System by combining heating and cooling functions i...

Page 46: ...BLOWER DEFROSTER DOOR HEATER OUTLET AIR CONDITIONER O N DOOR EVAPORATOR CORE COLD HEATER CORE AIR CONDITIONER OUTLETS AIR CONDITIONING CONTROLS AIR CONDITIONING O N KNOB AIR DOOR CIRCULATED m AIR FAN...

Page 47: ...speeds are controlled by turning the AIR PULL knob and the heater hot water valve vacuum switch is actuated by the COOL IN HQT PULL knob Air Conditioning ON Knob The AIR COND PULL knob controls the p...

Page 48: ...ined by the control knob temperature door setting and then enters the car Cooling operation is exactly the same except that the cooling core evaporator will be in operation at Ml capacity removing as...

Page 49: ...d be observed at all times All refrigerant drums are shipped with a heavy metal screw cap The purpose of the cap is to protect the valve and safety plug from damage It is good prac tice to replace the...

Page 50: ...POR H P POWER ELEMENT I I I M i I M Fig 38 Cycle of Operation Four Season and Comfortron LINE TO COMPRESSOR CLUTCH THERMOSTATIC SWITCH v CAPILLARY TUBING EXPANSION VALVE SIGHT GLASS COMPRESSOR Operati...

Page 51: ...oupling to which it is attached be held at the same time using three dif ferent wrenches to prevent turning the fitting and damaging the ground seat O rings and seats must be in perfect condition The...

Page 52: ...und metering refrigerant charging cylinder The use of a charging ey inder elim inates the need for scales hot water pails etc The chief advantage of this unit is savings A very definite savings in ref...

Page 53: ...as been shut off for several minutes to allow system pres sures to equalize This particularly applies to the front seal VACUUM PUMP A vacuum pump should be used for evacuating air and moisture from th...

Page 54: ...roughout the entire system mixed with the refrigerant a low refrigerant level will cause a dangerous lack of lubrication Therefore the refrigerant charge in the system has a definite tie in with the a...

Page 55: ...fittings On Universal and Four Season Systems the outlet line extends along side of and toward the front of the com pressor and the muffler in the line is bracket mounted to the compressor body In al...

Page 56: ...nt to remember that low pressure has a direct relationship to nozzle outlet temperature If pressure is too low ice will gradually form on the evaporator fins re stricting airflow into the passenger ar...

Page 57: ...he control head 4 Attach the black ground lead to any good ground point available in the car 5 Remove the large vacuum hose from Transducer and connect it to the Tester vacuum hose nipple 6 Connect th...

Page 58: ...ensor 6 If a bad sensor is indicated in Step 5 check each sensor disconnected from the system with an ohm meter Approximate resistance of each sensor at 75 F should be as follows In car Sensor 50 75 o...

Page 59: ...lower Motor CHECK Resistor I CHECK Electrical Diagram Probe Points 1 2 8 9 10 21 20 18 19 9 46 r 2 315 16 Checked during above procedure This is a com plete step by step high blower circuit check whic...

Page 60: ...auge readings based on the altitude where the readings are being taken Correct gauge reading at sea level is 29 5 psig Gauge readings will be one half psi higher for each additional 1000 feet of eleva...

Page 61: ...HEATER AND AIR CONDITIONING 1A 38 HIGH BLOWER DELAY RELAY O MASTER AND HIGH BLOWER DELAY RELAY GROUND Fig 49A Comfortron Wiring Diagram Underhood CHEVROLET CHASSIS SERVICE AAANUAL...

Page 62: ...N BROWN DK GREEN CONTROL SWITCH N CAR SENSOR ORANGE 36 y LT GREEN WWWW 55 jg TRANSDUCER POWER SERVO HIGH BLOWER MASTER FEEDBACK DELAY DELAY POTENTIOMETER THERMISTER THERMISTER Fig 49B Comforrron Wirin...

Page 63: ...er checks above the switch seems to be operating properly follows adjust for proper setting if necessary as 1 Chevy II All Weather Turn the outer air deflector in the face plate so that the attaching...

Page 64: ...installed power element bulb The first three conditions require valve replacement The last two may be corrected by replacing the valve inlet screen and by properly installing the power element bulb At...

Page 65: ...trip or attempt any valve adjustment EVACUATING AND CHARGING PROCEDURES 1967 AIR CONDITIONING SYSTEM CAPACITIES Four Season Systems Chevrolet and Chevelle Universal System Chevrolet Chevelle and Camar...

Page 66: ...ing and Charging System 1 Install charging station as previously described Refer to Figure 56 and 57 while performing the following operation 2 Remove Low Pressure gauge line from compressor 3 Crack o...

Page 67: ...GAGE VALVE WITH SCHRADER VALVE ADAPTER Attach to gage line before attaching to fitting HIGH PRESSURE GAGE VALVE H P LOW PRESSURE GAGE VALVE L P LOW PRESSURE VALVE P O A VALVE SYSTEM ALTERNATE R 12 CAN...

Page 68: ...al oil in the following amounts for any system components being replaced Evaporator 3 fluid oz Condenser 1 fluid oz Receiver Dehydrator 1 fluid oz NOTE When adding oil to the compressor it will be nec...

Page 69: ...rging Procedures 3 Inspect the O ring and the fitting and replace if damaged in any way Coat the O ring before re installed with refrigerati6n oil and install carefully 4 Retorque the fitting using a...

Page 70: ...ial If the screen is plugged replace it Reconnect the line to the expansion valve 5 Install a new receiver dehydrator 6 Install the replacement compressor 7 Add the necessary quantity of oil to the sy...

Page 71: ...ng on the new condenser 6 Set new condenser in place on the radiator support and install the attaching screws torquing them to 20 lbs ft 7 Make the inlet and outlet connections using new O rings and t...

Page 72: ...last instant before installation 5 2 3 Fig 63 Receiver Dehydrator Mounting Chevrolet Chevelle Chevy II Camaro Connect the high pressure lines at the inlet use a new O ring and torque connection to 13...

Page 73: ...hicle The duct assembly will be removed at this time also Core Replacement 1 With the evaporator assembly removed from the vehicle remove the expansion valve and its bulb 2 Remove the four nuts and bo...

Page 74: ...he thermostatic switch capillary and separate to the case halves 5 Remove the clamps from the evaporator inlet and qutlet pipes 6 Remove the screws which attach the evaporator to the case and remove e...

Page 75: ...HEATER AND AIR CONDITIONING 1A 52 Fig 68 Wiring and Vacuum Lines Four Season Chevrolet Fig 69 Underhood Wiring Four Season Chevelle CHEVROLET CHASSIS SERVICE MANUAL...

Page 76: ...ash tray retainer 5 Reach through the glove box door to disconnect the air conditioning on door bowden cable fig 75 6 Remove the two shield attaching screws and shield A fig 76 which covers the lower...

Page 77: ...his time 6 Remove the expansion valve power element from the low pressure line 7 Disconnecting the high pressure and low pressure lines from the valve remove the valve from the core 8 At this point ei...

Page 78: ...llation Within the Car 1 Attach system wiring as necessary to the evaporator case 2 Carefully pass the evaporator inlet and outlet pipes through the special grommet in the dash panel 3 Insert the evap...

Page 79: ...the heater water valve and vacuum line from the firewall and the heater hoses from the core pipes Carefully fold the hoses valve and tank away from the evaporator case 3 Remove the right hand hood lo...

Page 80: ...all the new core to the cover being sure that the grommets are properly installed around the inlet and outlet lines 12 Reinstall the core and cover assembly into the evap orator case and replace the a...

Page 81: ...ment bulb from the low pressure line and the equalizing line from the POA valve 3 Remove the low and high pressure connectors from the valve in that order Remove the screw and bracket attaching the ex...

Page 82: ...ng the low pressure high pressure and equalizing line connections and clamp the power element of the new valve to the low pressure line 5 Replace the core and evaporator as covered under Evaporator EV...

Page 83: ...o be replaced 4 Remove the switch knob Remove the switch retain ing screws and switch Installation 1 Insert replacement switch into face plate and attach 2 Install the switch knob and connect the wiri...

Page 84: ...attach the front and rear case halves 3 Remove clamp from the evaporator pipes and sep arate case halves 4 Remove face plate retaining screws located in outer ball outlets 5 Remove control knobs and r...

Page 85: ...switch and the blower motor Replacement 1 Disconnect the blower motor hot wire at the con nector and the ground lead on the Chevrolet 2 Detach the rubber cooling tube from the blower as sembly and re...

Page 86: ...on heater case studs and connect heater hoses 7 Replace evaporator pipe clamp and grommet 8 Replace the refrigerant hoses 9 Evacuate and charge the refrigeration system and refill the cooling system...

Page 87: ...or Duct Removal 4 Remove the remaining nuts attaching the blower and evaporator assembly and the cover assembly to the studs on the firewall 5 Replace the components removed by reversing the removal p...

Page 88: ...the radio receiver 3 Remove the electric clock 4 Remove the knobs nuts and bezels from the two air conditioning controls above the clock AIR COND PULL and COLD IN HOT PULL 5 Carefully pull the outlet...

Page 89: ...the core cover was removed in Step 2 located at the right end of the air dis tributor assembly 14 Carefully pull the assembly out from under the dash disconnecting the compressor switch wiring connect...

Page 90: ...ent 3 Remove the Comfortron control assembly mounting screws and lower the control unit 4 Remove the vacuum line from the kick pad valve diaphragm 5 Disconnect all harness connectors between the Com f...

Page 91: ...cuum tank ports Thermal Vacuum Valve This heat operated vacuum valve is located in the heater core input line Figure 98 illustrates valve instal lation with clamps attaching the water hoses as well as...

Page 92: ...tment 1 Install Tester J 22368 as previously described 2 Set Tester Voltage switch to Control Calibrate position 3 Start the engine fast idle and set Comfortron Control lever to HI FRONT 4 Switch Rock...

Page 93: ...re 109 HIGH BLOWER DELAY RELAY MASTER DELAY RELAY Fig 100 Comfortron Relays COLLISION PROCEDURE AII Systems Whenever a car equipped with air conditioning unit is involed in a collision or wreck it sho...

Page 94: ...or the entire unit processed where damaged or exposed to the atmosphere e All connecting lines and flexible hoses should be examined throughout their entire length for dam age If damaged in any manner...

Page 95: ...HEATER AND AIR CONDITIONING 1A 72 Fig 103 Comforrron Underhood Vacuum Lines Fig 104 Comfortron Underdash Vacuum Lines CHEVROLET CHASSIS SERVICE MANUAL...

Page 96: ...duct beneath the instrument panel A significant difference is that in the Corvette Air Conditioning System there is no flow through the heater core until the COOL IN HOT PULL knob is pulled out This m...

Page 97: ...g screws 2 Attach the heater housing cover to the housing 3 Position the unit against the firewall and attach it with the retaining screw at the top of the case 4 Attach the sheet metal nuts to the ca...

Page 98: ...butor Assembly 2 Remove the screws attaching the die cast plate to the air inlet side of the case Disconnect the tem perature door linkage at the door shaft 3 Remove the die cast plate with core from...

Page 99: ...ly drain and measure oil in the compressor Check for evidence of contamination to determine if remainder of system requires servicing Compressor Servicing information is located in the Chassis Overhau...

Page 100: ...in the Tune Up chart in the Engine section of this manual COMPRESSOR FAILURE If the compressor has failed mechanically to the ex tent that metal chips and shavings are found in it the system should be...

Page 101: ...gh Resistance in series with Bio Motor Hi Rl RiR2 Rl R2 None Blower switch contacts must be dosed before fan switch will be operable COLD O A COLD a A Blower H y low s w i t c h M med Norm closed cont...

Page 102: ...COMPRESSOR SW OFF POSN ON POSN RELAY ASM DASH PANEL RESISTOR ASM LUTCH COIL OMI GRD WIRE ASM MPRESSOR BAT TERM ON START MTR SOL EXTENSION WIRE ASM _ J J CONTROL SW CONTACTS B TO NONE B T O L BTOL M B...

Page 103: ...must be closed before fan switch will be operable To battery positive 0 terminal Horn relay terminal Batf To vacuum tank EXTENSION WIRE ASM Normally closed contacts vac operated 7 Fan speed switch See...

Page 104: ...DASH y V PANEL GROMMET 1 _ J 14 BLACK RED STRIPE FUSE 20 AMP WIRE ASM BLOWER MOTOR 14 BLACK 1 IGNITION SWITCH1 ACCESSORY TERMINAL CONTROL SWITCH RESISTOR CONN 14 TAN 16 BLACK LIGHT BLUE STRIPE THERMOS...

Page 105: ...NEGATIVE CABLE COMPRESSOR ASM DASHPAJSTEL GROMMET 16DG CONTROL SWITCH RESISTOR ASM 14LBL 14BRN CLUTCH COIL EXTENSION WIRE ASM 1 4 B R N N JUNC BLOCKi OSTATIC SWITCH CONTACTS NORMALLY CLOSED STARTING M...

Page 106: ...SWITCH SET AT OFF LOW MED HIGH CONTACTS BTOBL BTOL BTOM BT0M6B CLUTCH HOUSING l i O l i WHEN CONTROL SWITCH IS AT OFF AIR COND IS ON FAN WILL RUN AT LOW SPEED AIR COND PULL KNOB SHOWN IN ON POSITION T...

Page 107: ...Pocket Thermometers 2 21 Snap Ring Pliers 26 Snap Ring Pliers Compressor Holding Fixture Compressing Fixture 16 J 9403 17 J 9399 18 J 9401 19 J 9480 20 J 9392 21 J 9393 22 J 9298 23 J 9481 24 J 8092 2...

Page 108: ...Instructions 1B 27 Repair Panels 1B 28 Precautions 1B 29 Plastic Solder Kit 1B 29 Resin Kit 1B 30 Specific Repairs 1B 32 Scratched Panels Spot Refinishing 1B 32 Dents in Panels Surface Cracks B 33 Cra...

Page 109: ...ing hinge straps and support assembly to hood If hinges are removed from vehicle note amount of shims under each hinge Installation In replacing original hood align hinge with scribe marks made on rem...

Page 110: ...CORVETTE BODY 1B 3 VIEW A RETAINER VIEW C 2PA II 26 Fig 2 Hood Hinge and Catch CHEVROLET O...

Page 111: ...ion is illustrated in Figure 9 REAR VIEW MIRROR Outside Removal The outside rear view mirror may be removed from the door by removing the set screw located on the in board side of the mirror support w...

Page 112: ...arking molding and header rail to ease reinstallation as shown in Figure 14 4 Mark position of lower reveal molding as shown in Figure 15 and pry molding out of weatherstrip 5 From inside vehicle care...

Page 113: ...cord long enough so that about 10 of free length exists after going around windshield Knot ends of cord together where they meet at bot tom center of glass and draw knot into groove fig 21 Tape loose...

Page 114: ...need for emergency spacers pro ceed as follows 1 With pencil scribe position of striker on body pillar 2 Remove three door lock striker attaching screws and remove striker and adjusting plates from pi...

Page 115: ...l Molding Caps 4 Side Reveal Molding 67 5 Upper Reveal Molding Retainer 67 only 6 Upper Reveal Molding Retainer Nut 67 only 7 Side Reveal Molding Upper Retainer 67 only 8 Side Reveal Molding Upper Ret...

Page 116: ...ving Garnish Moldings Fig 14 Removing Upper Reveal Molding Fig 16 Removing Weatherstrip From Frame Fig 17 Windshield Checking Blocks Fig 15 Removing Lower Reveal Molding Fig 18 Windshield Glass On Blo...

Page 117: ...as desired by installation or re moval of shims located between hinge rear strap and door fig 27 To adjust door proceed as follows 1 Remove door trim panel as outlined in this section 2 Remove lock s...

Page 118: ...ay be necessary TRIM PANEL AND INSIDE HANDLES Figure 29 is an exploded view of integral arm rest inside handles and trim panel fastenings Removal of trim panel may be accomplished as follows 1 Remove...

Page 119: ...Remove regulator mounting screws 3 and regula tor support mounting screws 3 remove mounting plate 6 Remove window drive pin retaining screw and re move regulator from drive pin 7 Remove ventilator as...

Page 120: ...ssary as outlined under Doors Adjustments Door Windows Ventilator Window Assembly Replacement Window and frame assembly may be replaced without removing entire ventilator assembly from vehicle Pro cee...

Page 121: ...er WINDOW OUTER SEAL ASSEMBLY Removal 1 Remove door trim panel as outlined in this section 2 Remove door window assembly as outlined in this section 6 Regulator Support 7 Regulator 8 Ventilator Assemb...

Page 122: ...W REGULATOR POWER In cases where window will not operate check electri cal connections first Figure 44 illustrates lpcation of junctions switches and circuit breaker Removal Perform operations 1 thru...

Page 123: ...ontrol assembly and disengage control from remote control locking rod 6 Remove 4 screws retaining lock assembly disengage control rods and remove lock from door pocket Installation To install lock and...

Page 124: ...Disengage cylinder from rod and remove cylinder and escutcheon from door Fig 37 Removing Sash Retaining Screws 4 Installation may be made by following removal pro cedure in reverse order HINGES DOOR A...

Page 125: ...power windows replace wiring 5 Replace all trim removed upon disassembly Fig 39 Window Run and Seal Assembly 3 If entire door is to be removed and door has elec tric power window disconnect and remov...

Page 126: ...inge frame and compartment floor 3 To remove spring from hinge assembly close top compartment lid as far as possible and insert Tool J 9559 between expanded coils in spring Opening top compartment lid...

Page 127: ...rews and remove control from compartment lid Installation 1 Position control on compartment lid and install mounting screws 2 Install ends of cables in control and fasten securely with retainers 3 Tes...

Page 128: ...ve cement rubber spacers at bottom sides and top of window opening The step type spacers are used at bottom and sides the flat type are used at the top sides and bottom of window opening as shown on F...

Page 129: ...nd apply sufficient material to fill void and to dispense the bubble before continuing The reveal molding clips are self sealing and do not require sealing before installing the rear glass With aid of...

Page 130: ...ws located on inner circumference of bezel Trim plate is retained by five special nuts which are accessible from under right rear corner of vehicle REAR FILLER PANEL Removal 1 Remove rear license plat...

Page 131: ...g Hinge Spring Installation Installation may be made by following removal pro cedure in reverse order Before installing swivel bolt assembly coat nut and bolt threads with chassis grease Fig 52 Foldtn...

Page 132: ...brics Care of genuine leather and coated fabrics includes vinyl coated formed headlining is a relatively simple but important matter The surface should be wiped oc casionally with a dry cloth and when...

Page 133: ...TRIM For parts identification refer to Figure 64 Soft Covers The soft covering is cemented to the body in rear window area Replacement of all or part will require removal of rear window garnish moldi...

Page 134: ...on lower edge of seat back BODY MOUNTING Figure 65 illustrates underbody attachment to frame body mounting brackets Shims which are shown on rear crossmember are cemented in place The torque of all bo...

Page 135: ...ind that the part being used to brace the stationary end of tool must be able to withstand such usage and that fiber glass parts though tougher than steel will not yield or take a set as with steel pa...

Page 136: ...sin may be evident Washing in cold water will help to minimize 4 Use a belt sander with a vacuum attachment for dust control if possible 5 Resin mixtures may produce toxic fumes and should be used in...

Page 137: ...vertical surfaces several layers may be used each about 1 2 thick 4 Finish the repair by grinding sanding and painting in the usual manner Figure 74 RESIN KIT The Resin Repair Kit for major repairs co...

Page 138: ...ent Door Outer Panel inner 9 Cover Rear Access Hole 10 Pillar Assembly Door Lock 11 Panel Door Lower Inner 12 Sill Door 13 Molding Rocker 14 Panel Side Door Outer 15 Panet Door Hinge Reinforcing 16 Re...

Page 139: ...ION Cleanliness is most important Be certain all containers are dry and clean and the resin and hardener cans are kept closed when not in use Do not use waxed cups for mixing and do not allow resin to...

Page 140: ...wet or dry paper Figure 79 CAUTION Do not sand too deeply into fiber glass mat Should it be necessary to cut fairly deep into the glass mat use the repair pro cedure suggested for dents and pits in p...

Page 141: ...ock Pillar Right Hand 18 Panel Rear Quarter Right Hand 19 Shield Rear Quarter Splash 20 Panel Body Rear Upper 21 Extension Body Rear Upper Panel Support Right Hand and Left Hand 22 Bonding Strip Body...

Page 142: ...t down to the plastic form area sur rounding the damage with Lacquer Removing Solvent or its equivalent 2 Scuff area surrounding damaged area to provide a good bonding surface 3 Clean up work area wit...

Page 143: ...move paint and scuff area clean to provide a good bonding surface Remove all cracked and fractured material along the break Bevel the attaching edges of the panels at approximately a 30 angle with a f...

Page 144: ...or filing all cracked and splintered material away from the fracture 2 Bevel the edge of the fracture at approximately a 20 angle 3 Remove paint from area surrounding fracture with Lacquer Solvent or...

Page 145: ...ow Reveal Molding Upper 12 Frame Window Lower 13 Plate Inner 14 Plate Outer 11 Trim excess or loose strands of fiberglass from patch 12 If low spots exist prepare another plastic mixture of resin and...

Page 146: ...ch or surrounding panel 16 Use plastic solder as necessary to fill any imperfections 17 Allow fill to harden then sand finish preparatory to paint operation Fig 86 Installing Reveal Molding Retainers...

Page 147: ...ll be formed on the finish surface when 3 4 Fig 90 Pulling Cord From Weatherstrip the pieces are joined If the replacement panel does not fit closely to the break reshape to suit 5 Cut two backup piec...

Page 148: ...circulation The hard top rear window is plexiglas and should be cared for in exactly the same manner as outlined for the convertible top rear window see Care of Folding Top in this section Never scra...

Page 149: ...of seal is pulled out of frame apex and over frame flange When string has been removed carefully inspect seating of lip over entire perimeter of window paying particular attention to corners Remove ta...

Page 150: ...mation which follows weatherstrip instructions Inner Forward Weatherstrips Item 9 Fig 97 These are cemented to inner side weatherstrips item Fig 96 Cleaning Top Inner Surface 5 Figure 97 and are retai...

Page 151: ...ver lengthwise Lay cover on roof panel Determine overhang approximately 1 4 Apply nitrile non staining vinyl trim adhesive such as 3M Vinyl Trim Adhesive to the ropf panel ad jacent to center line of...

Page 152: ...Frame Window Lower 13 Plate Inner 14 Plate Outer minimum of 1 2 flange which will be cemented to substructure of removable hardtop with adhesive 11 Reinstall reveal moldings and weatherstrips Vinyl R...

Page 153: ...excess heat may cause permanent damage to vinyl roof cover 5 Remove towel and4nspect area If slight wrinkles or blisters are still present perform the following steps 6 Using a syringe and hypodermic...

Page 154: ...Top Trim Installation 1 To remove superficial dust do not use a dry cloth Use a soft cotton cloth moistened with water and wipe cross wise of the window 2 To wash the rear window use cold or tepid not...

Page 155: ...dow 3 When removing frost snow or ice from the plastic window DO NOT USE A SCRAPER In an emer gency warm water may be used Use care that the warm water does not contact the glass windows or windshield...

Page 156: ...ditions such as poor top fit at upper and rear edge of windows faulty fore and aft engagements of rear bow hold down pins in lock assem blies and loose or oversight top rear panel when top is raised a...

Page 157: ...stments TOP TRIM AND REAR WINDOW ASSEMBLY The following information deals with removal and installation of the folding top trim and window assembly complete Figure 102 may be referred to for parts ide...

Page 158: ...securing top and header outer weatherstrip to header Figure 103 3 Pull cemented trim from rear side rail Section C C REWORK PART 6280765 GRIND OFF THIS PORTION COAT TIP WITH GREASE PENCIL II INSTALL...

Page 159: ...lation The pivoting joints should be lubricated with light machine oil once a year Apply oil sparingly so as not to stain top trim WEATHERSTRIP Side Rail Weatherstrip Figure 111 illustrates installati...

Page 160: ...imp ferrule tabs 15 With aid of an assistant place the hardtop onto the vehicle and install attaching parts at all four loca tions Lock latches at windshield header SPECIAL TOOLS 1 J9559 Hood Spring T...

Page 161: ...t of the car should be supported at the wheel locations 3 A visual damage inspection should be made to elim inate needless measuring Obviously damaged or misaligned areas can often be located by sight...

Page 162: ...39 y2 CONVERTIBLE H 78 109Vr 2 124 157 ALL DIMENSIONS TO HOLES ARE MEASURED TO THE CENTER OF THE HOLES 0 INDICATES THAT THE DIMENSION IS TO THE UNDERSIDE OF EITHER THE FRAME TOP SURFACE OR BODY MOUNT...

Page 163: ...62 STW PICK UP 120 235 8 145 35 SEDAN CPE CONV ALL DIMENSIONS TO HOLES ARE MEASURED TO THE CENTER OF THE HOLES eio L_ 123 4 19 195 8 42 2 33 90 0 INDICATES THAT THE DIMENSION IS TO THE UNDERSIDE OF E...

Page 164: ...18 A 36V4 CONV ONLY 69 JI C ALL DIMENSIONS TO HOLES ARE MEASURED TO THE CENTER OF THE HOLES 0 INDICATES THAT THE DIMENSION IS TO THE UNDERSIDE OF THE FRAME TOP SURFACE OR BODY MOUNT Fig 3 Frame Dimen...

Page 165: ...I 3 17 Inspection 3 17 Removal 3 17 Installation 3 17 Lube Fittings 3 18 Lower Control Arm 3 18 Chevrolet 3 18 Removal 3 18 Installation 3 18 Chevelle and Camaro 3 18 Removal 3 18 Installation 3 18 Ch...

Page 166: ...FRONT SUSPENSION 3 2 Fig 1 Front Suspension Chevrolet Fig 2 Front Suspension Chevelle Camaro CHEVROLET CHASSIS SERVICE MANUAL...

Page 167: ...bearing adjustment has a definite bearing on the safe operation of a vehicle Improperly adjusted front wheel bearings will result in a lack of steering stability causing wheel wander shimmy and ex ces...

Page 168: ...NTROL ARM LOWER CONTROL ARM STRUT ROD STEERING KNUCKLE Fig 4 Front Suspension Chevy STEERING AXIS VERTICAL CASTER ANGLE CASTER WHEEL PLANE VERTICAL PLANE CAMBER ANGLE STEERING AXIS INCLINATION CAMBER...

Page 169: ...ating properly Wheel alignment should always be made with the vehi cle rolled forward taking out any slack in the same man ner as when the vehicle is traveling forward Caster and Camber Adjustment NOT...

Page 170: ...the end of this section NOTE Toe in must be adjusted after caster and camber adjustment A If the equipment being used measures the toe in of each wheel individually 1 Set the steering gear on the high...

Page 171: ...floor to the outer pivot which is located 1 8 12 inboard from the ball stud boss at the lower surface of the arm Chevy II Measure the distance from the floor to the lower ball joint seat Corvette Meas...

Page 172: ...Lower vehicle to floor tighten hub wheel nuts and in stall hub cap FRONT WHEEL HUB Replacement 1 Remove hub caps break loose the wheel stud nuts VM DIA PIPE OR ARBOR l INNER CUP OUTER CUP JL RADIUS e...

Page 173: ...If a frame hoist is used support lower control arm with an adjustable jackstand to safely retain spring in its curb height position Chevy n While vehicle weight is still on front wheels position suppo...

Page 174: ...vehicle recheck and readjust wheel alignment where necessary SHOCK ABSORBER Chevrolet Chevelle Comoro and Corvette Fig 14 Removal 1 With an open end wrench hold the shock absorber upper stem from turn...

Page 175: ...washers must correctly pilot into spring seat 4 Install upper mounting bracket to spring tower and torque nuts according to Specifications at the end of this book STABILIZER BAR FIG 17 Removal 1 Rais...

Page 176: ...end wrench hold the shock absorber upper stem from turning and then remove the upper stem retaining nut retainer and rubber grommet I IVi rVi i j ii I 5 4 s WOOD BLOCK USED WITH CHEVROLET ONLY Fig 19...

Page 177: ...rod end and the wheel and tire 7 Lower vehicle to floor and install the shock absorber upper stem retaining nut retainer and grommet 8 Check the camber adjustment Chevelle and Camaro Removal 1 With an...

Page 178: ...upper con trol arm and the frame will simplify this operation 2 Replace the stabilizer bar link shock absorber and wheel and tire 3 Lower vehicle to floor and install the shock absorber upper stem ret...

Page 179: ...compressed just enough to clear the spring tower then remove the lower ball joint to steering knuckle nut fig 22 NOTE It may be necessary to assist the spring out of the spring tower with a pry bar o...

Page 180: ...does not indicate excessive wear inspect further as follows 5 On Chevrolet Only Examine lubrication hole in each joint assembly after cleaning out hole Look for evi dence of the liner partially or ful...

Page 181: ...secure in place with the attacking nut and install the cotter pin 1 With upper control arm support in position as in Figure 15 disconnect the lower ball stud from steer ing knuckle 2 Assemble nut to l...

Page 182: ...m ball stud cotter pin and loosen nut Loosen the ball stud then remove nut and lower control arm CAUTION Use extreme care not to damage the seal during this operation Installation 1 Insert lower contr...

Page 183: ...Corvette Fig 30 Removal 1 Remove the front coil spring as outlined under Front Spring Removal 2 Remove the two front cross shaft to frame attaching bolts and lock washers and the rear frame attaching...

Page 184: ...rn down on the puller screw nut to install the bushing in the control arm Chevelle and Camaro Large Bushing Removal and Installation 1 Remove the lower control arm 2 To remove the large bushing use To...

Page 185: ...rque required to rotate the ball stud in the assembly After performing the first four steps under Replacement below install a stud nut on the stud and measure the torque required to turn the stud in t...

Page 186: ...e lube fitting Therefore it will be necessary to install a self threading type fitting into the untapped hole pro vided when replacing the entire assembly UPPER CONTROL ARM Chevrolet Chevelle Camaro a...

Page 187: ...and adjust where necessary UPPER CONTROL ARM CROSS SHAFT AND OR BUSHINGS Chevrolet Chevelle and Camaro Removal 1 Remove cap screws lock washers and collars from 2 3 4 both ends of cross shaft 2 Insta...

Page 188: ...a x 24 y CAP SCREW k a 4f TOOL i J 5888 3 Fig 41 Removing Upper Control Arm Cross Shaft Bushings 3 Insert J 9513 1 over threaded end of pivot shaft 4 Press pivot shaft down until upper bushing diamete...

Page 189: ...ross shaft 2 Install a 3 8 24 cap screw furnished with Tool J 5888 in one end of cross shaft 3 Support control arm in an arbor press on Tool J 5888 3 as shown in Figure 41 NOTE Be certain flange of bu...

Page 190: ...9519 7 Front Suspension Special Tools Installer Installer Remover Remover Remover Remover Installer Spacer Remover 19 J 9519 10 20 J 9519 16 21 J 9519 17 22 J 21058 8 23 J 21058 15 24 J 21474 2 25 J...

Page 191: ...4 17 Installation 4 17 Component Parts Replacement Corvette 4 17 Wheel Spindle and Support 4 17 Removal 4 17 Repairs 4 17 Installation 4 18 Differential Carrier Support Bracket Replacement 4 20 Shock...

Page 192: ...pring bracket which has a vertical flange to retain the spring Sideways movement of the axle assembly is controlled by two angularly mounted rubber bushed upper control arms Projecting ears cast as pa...

Page 193: ...The springs are positioned to the axle spring seats by locating pins butt welded to the spring leaf CORVETTE The Corvette independent three link type rear sus pension consists of a fixed differential...

Page 194: ...orts also incorporate integrally forged fork shaped mounting brackets to accept the outer ends of the rubber bushed strut rods The strut rods are mounted laterally from the spindle support to a bracke...

Page 195: ...kick up fig 6 4 On Chevy II models measure riding height as the distance from lower surface of bumper support bracket to top of axle housing fig 7 5 On Camaro models measure riding height as the dist...

Page 196: ...ed in this section 1 Raise rear of vehicle until wheels clear ground 2 Disengage bolt lock tabs and disconnect outboard end of axle drive shaft from wheel spindle flange 3 Mark camber cam in relation...

Page 197: ...ginal position and torque all components to specifications COMPONENT PARTS REPLACEMENT Chevrolet Chevelle Chevy II and Camaro COIL SPRING Chevrolet Removal To remove either or both rear coil springs p...

Page 198: ...Raise vehicle to a height that will allow axle assem bly to hang freely and position supports under both frame side rails 2 Support axle assembly with an adjustable lifting device and disconnect shoc...

Page 199: ...ssive wear or aging and replace as necessary Inspect spring rear shackles front spring bracket and eye bolt for bending or cracking and correct where needed 2 Assemble spring rear shackle as follows a...

Page 200: ...he spring retainer bracket to the underbody 6 Lower axle assembly sufficiently to permit access to spring retainer bracket and remove bracket from spring 7 The spring eye bushing can be replaced witho...

Page 201: ...d axle bracket so that spring cushion ribs align with axle bracket locating ribs 7 Place lower spring cushion on spring so that cushion is indexed on locating dowel Upper cushion and 8 Place lower mou...

Page 202: ...que to specifications 4 Lower vehicle and test shock absorber action Comoro Removal Refer to Fig 29 1 Raise rear of vehicle and support rear axle assembly 2 Loosen and remove shock absorber lower atta...

Page 203: ...Adapter J 21830 2 is centered and will clear hole in control arm 4 Disassemble puller tools and position Installer Adapter J 21830 2 on flanged end of new bushing Install Spacer J 21830 6 over small...

Page 204: ...Remove assembly from vehicle Bushing Replacement Lower control arm front and rear bushing assemblies are not interchangeable and require separate removal and installation procedures 1 Replace the fron...

Page 205: ...8 until bushing is fully seated J 21058 8 J 21830 7 J 21830 4 J 21830 3 J 21830 2 J 2K X D58 8 J 21830 7 IP he 21830 4 J 21830 2 JfSir J 21830 3 Fig 35 Lower Control Arm Rear Bushing Removal Chevrolet...

Page 206: ...bushing then place assembly through hole in control arm NOTE Bushings are installed in one direction only flanged end of bushing seats against rolled cutout side of control arm e Install Receiver J 2...

Page 207: ...thdraw bushing from carrier ear Refer to Figure 41 for installed view of removal tools Position Installer J 21474 2 on flanged end of new bushing and install Driver Handle J 7079 2 to opposite end of...

Page 208: ...ers and use as shown in Figure 47 After removing deflector spindle inner grease seal and inner bearing race bearing cups may be re moved while spindle support is still mounted to the torque arm by ins...

Page 209: ...of bearing should be toward shoulder on spindle e Press bearing on spindle using a bearing spacer and Tool J 9436 as installers as shown in Fig ure 50 5 Pack spindle inner bearing with a high melting...

Page 210: ...ntil bolt head contacts floor well Mark the floor well at this point and drill a 3 4 diameter hole for each bolt in floor well and remove bolts 5 Assemble carrier support bracket by reversing above pr...

Page 211: ...and slide rod into bracket Install cam and bolt assembly and adjust cam to line up with mark on bracket Tighten nut but do not torque at this point SPRING LINK BOLT SPRING CUSHION SPRING CUSHION CENTE...

Page 212: ...pletely released 7 Repeat Steps 2 6 on other side 8 Remove four bolts and washers securing spring center clamp plate fig 58 9 Drop spring and slide out from under vehicle fig 59 Repairs 1 Clamp spring...

Page 213: ...move shock absorber lower eye from strut rod shaft 3 Disconnect and remove strut rod shaft and swing strut rod down 4 Remove four bolts securing axle drive shaft to spindle flange and disconnect drive...

Page 214: ...ning 2 Place toe in shims in original position on both sides of torque arm install pivot bolt and tighten but do not torque at this point Fig 67 Flaring Tool Back Up Plate Corvette 3 Raise axle drive...

Page 215: ...ications 3 Install differential carrier assembly as outlined under Differential Carrier Installation in this section 4 Install wheels and tires remove frame supports and lower vehicle STABILIZER SHAFT...

Page 216: ...brake flange plate attachment The overhung hypoid drive pinion is supported by two preloaded tapered roller bearings The pinion shaft is sealed by means of a molded spring loaded rubber seal The seal...

Page 217: ...Drive Pinion MAINTENANCE AND ADJUSTMENTS The lubricant level should be periodically checked and maintained at level of filler plug with a warm axle See the lubrication section of this manual for lubr...

Page 218: ...ng 4 Rear Pinion Bearing 5 Pinion Shim 6 Pinion 7 Differential Pinion 8 Differential Side Gear 9 Differential Bearing 10 Differential Bearing Shim 11 Yoke Bearing 12 Yoke Bearing Seal 13 Side Gear Yok...

Page 219: ...drive float or coast conditions Gear noise tends to peak in a narrow speed range or ranges while bearing noise will tend to remain constant in pitch Ab normal gear noise is rare and usually originates...

Page 220: ...t arid secure axle assembly with an adjustable lifting device On Chevrolet and Cheveile models loosen upper and lower control arm attaching bolts at axle housing On Chevrolet models disconnect tie rod...

Page 221: ...ing outer x race Remove bearing using slide hammer as shown in Figure 79 Figure 80 shows a detail of axle housing outer end 3 Lubricate new bearing with wheel bearing lubricant and install bearing so...

Page 222: ...Separate rear universal joint tape trunnion bearings to joint position propeller shaft to one side and tie it to frame side rail 4 Using Tool J 5853 with Adapter J 5810 and a suitable socket on the p...

Page 223: ...e position of the pinion and flange was previously marked so that reinstallation may be made with flange and pinion in same relative position CAUTION Do not attempt to hammer flange onto pinion shaft...

Page 224: ...om the bottom This will prevent air pockets and en sure an adequate supply of lubricant 7 Place new dust seals on trunnion cavity of seal toward end of trunnion then position Tool J 21556 over end of...

Page 225: ...ove companion flange by driving off with brass drift and hammer fig 93 10 Using screw driver pry oil seal out of carrier Inspection Inspect companion flange splines for excessive wear or twisting and...

Page 226: ...drain out 8 With mounting bolts removed pull carrier partially out of cover drop nose to clear crossmember and gradually work carrier down and out Installation 1 Clean inside of carrier cover and libe...

Page 227: ...torque wrench attached to J 5748 Torque should be 70 ft lbs minimum new and no less than 40 ft lbs if used PROPELLER SHAFT AND UNIVERSAL JOINTS INDEX Page Page General Description 4 37 Component Part...

Page 228: ...oval 1 Raise vehicle mark relationship of shaft to com panion flange and disconnect the rear universal joint by removing trunnion bearing U bolts fig 101 Tape bearing cups to trunnion to prevent dropp...

Page 229: ...t seals on trunnions cavity of seal toward end of trunnion then position Tool J 21548 over end of trunnion and into cavity portion of seal Press seal onto trunnion until tool bottoms against trunnion...

Page 230: ...zontal position b Using a piece of pipe or similar tool with an ins side diameter slightly larger than 1 1 8 press bearing from yoke fig 108 c Apply force on yoke around bearing until nylon retainer b...

Page 231: ...aft b Insert trunnion into yoke fig 111 c Firmly seat trunnion into bearing cup and press bearing cup into yoke until it is flush with yoke d Install opposite bearing cap and seal making sure that rol...

Page 232: ...rol Arm Bushing Remover Consists of J 21474 5 Receiver J 21474 1 Spacer and J 21474 2 Adapter Drive Pinion Oil Seal Installer Light Duty Axle Used with J 21468 10 J 21051 Rear Wheel Bearing and Oil Se...

Page 233: ...earing Remover 6 J 7877 Strut Rod Bushing Replacement Sef 7 J 7817 Wheel Drive Spindle Bearing Cup Installer 8 J 21548 Propeller Shaft U Joint Trunnion Seal Installer 9 J 21556 Axle Drive Shaft U Join...

Page 234: ...ical pressure from the brake pedal push rod and transmit it through the brake lines as hydraulic pressure to the wheel cylinders The filler cap is accessible from inside the engine compartment A new b...

Page 235: ...transmits it to the equalizer by means of the front cable The one piece rear cable passes through the equalizer and is connected at each end to an actuating lever within the rear brake assembly The C...

Page 236: ...en failed chamber is bottomed the pedal will harden HYDRAULIC BRAKE FLUID Use GM Hydraulic Brake Fluid Supreme No 11 or equivalent when servicing brakes This brake fluid is satisfactory for any climat...

Page 237: ...lled during adapter Fig 6 Brake Bleeder Adapter Tool J 22489 Installed Remove bleeder dry of fluid if removal 12 Fill master cylinder reservoirs to within 1 4 of reservoir rims as shown in Figure 8 13...

Page 238: ...twist which they encounter during normal vehicle usage The hoses require no service other than periodic inspection for damage from road hazards or other like sources Should damage occur and replacemen...

Page 239: ...he brakes will become ineffective CAUTION When necessary to replace brake tubing always use special steel tubing which is designed to withstand high pressure and re sist corrosion Ordinary copper tubi...

Page 240: ...nt distortion of the plate Remove the punch and the ram Now reverse the punch and put it back into the tool body Install the ram and tap it lightly until the face of the upset flare punch contacts the...

Page 241: ...t reverse vehic motion may prevent the automatic adjuster from functioning thereby inducing low pedal heights Fig 18 Aligning Drum Tang with Wheel Hub Parking Broke The rear brake assemblies serve a d...

Page 242: ...fully expanded and secured in cutout then position cable ball into pedal assembly swivel 3 Feed stud end of cable through frame rail and se cure with retainer on inner side of frame 4 Place one check...

Page 243: ...BRAKES 5 10 Fig 19 Parking Brake System Chevrolet and Chevelle CHEVROLET CHASSIS SERVICE MANUAL...

Page 244: ...ery to eliminate possibility of creating short cir cuits under dash 1 Place parking brake lever in released position 2 Eemove return spring at equalizer 3 Remove equalizer check nut and separate cable...

Page 245: ...e in bracket with clamp s 5 Place one check nut on cable stud and insert stud into equalizer then place second check nut on stud 6 Connect cable return spring 7 Adjust parking brake as outlined in thi...

Page 246: ...ase 10 Adjust rear service brakes and parking brake as outlined in this section BRAKES 5 13 PARKING BRAKE CORVETTE Fig 22 Lever Assembly Removal 1 Place parking brake lever in the fully released posit...

Page 247: ...lever removal procedure above 2 Under vehicle remove nut washer and bolt se curing pulley to pulley bracket fig 22 3 Remove seal grommet from underbody cable hole 4 Pull front cable out of vehicle In...

Page 248: ...agent of any nature 3 Inspect all nylon bushings for wear and damage 4 Inspect mating surface of bushings for wear and damage replace parts as required Installation 1 Lubricate and install nylon bush...

Page 249: ...spring are an assembly It is not recommended that they be disassembled for service purposes unless they are broken It is much easier to assemble and disassemble the brakes by leaving them intact 8 Se...

Page 250: ...0 Install the wire link NOTE Do not hook the wire link over the anchor pin stud with the regular spring hook tool This may damage the cylinder boot seals Fasten the wire link to the actuator assembly...

Page 251: ...indicate the difference between a worn and satisfactory shoe When the bonding pad begins to appear through the brake facing material a bright finish will appear fig 31 To preclude the possibility of...

Page 252: ...t the push rod end as the piston which is removed Delco Moraine dual master cylinders used with drum type brakes contain a rubber check valve and check valve spring in each outlet boss When the car is...

Page 253: ...dry the parts and place on clean paper or lint free clean cloth NOTE Be sure to keep parts clean until re assembly Rewash parts if there is any occa sion to doubt cleanliness 4 Check pistons for scra...

Page 254: ...7 Piston Cup 3 Piston Cup 8 Piston 4 Housing 9 Push Rod Boot 5 Fluid Inlet 2 Remove wheel and tire assembly Back off brake adjustment if necessary and remove drum 3 Disconnect brake system hydraulic l...

Page 255: ...out of round Any of these conditions must be corrected since they can impair the efficiency of brake operation and also can cause premature failure of other parts Smooth up any slight scores by polish...

Page 256: ...h in position and secure to bracket with mounting screw 3 Remove protective material from open hydraulic brake lines and connect lines to switch If necessary tighten brake line connections at main cyl...

Page 257: ...r brakes as applicable resulting in the correct pressure balance between the front and rear hydraulic systems This valve guards against premature lock up of front or rear wheels when brakes are applie...

Page 258: ...etely or air will be pumped into the system 2 Raise vehicle and place on jackstands 3 Remove wheels 4 Remove and discard the cotter pin from the inboard end of the shoe retaining pin and slide out the...

Page 259: ...n this section 10 Install wheels and lower vehicle BRAKE CALIPER Removal 1 Raise vehicle and place on jackstands 2 Remove wheel 3 On front caliper disconnect the brake hose at brake line support brack...

Page 260: ...emoved push the piston down into the caliper as far as it will go Insert a screwdriver blade under the inner edge of the steel ring in the boot and using the piston as a fulcrum pry the boot from its...

Page 261: ...ed face of the caliper Any distortion or uneven seating could allow con taminating and corrosive elements to enter the bore 8 Position the t O rings in the small cavities around the brake fluid transf...

Page 262: ...han this can permit the shoes to come out of contact with the shoe abutments and cause malfunction Because performance is not impaired by surface im perfection not exceeding 015 deep refinishing of th...

Page 263: ...sting screw 2 Attach adjusting screw spring to the bottom hole in each shoe 3 Insert the star wheel between the shoes On left hand brakes the star wheel goes next to the rear shoe on right hand brakes...

Page 264: ...edal and push rod LUBRICATION The power brake unit is lubricated at assembly and needs no further lubrication other than maintaining normal reservoir fluid level The reservoir should be filled as desc...

Page 265: ...e Spring Remover and Installer 3 J 8113 Brake Tube Cutter 4 J 22591 J 22629 J 22639 Piston Ring Compressors 5 J 21472 Brake Bleeder Wrench 6 J 22489 Pressure Bleeder Adapter 7 J 21177 Drum ro Brake Sh...

Page 266: ...ed if the technician will follow a definite and thorough procedure of analysis and correction of all items affecting power performance and economy The tune up will be performed in two parts The first...

Page 267: ...under Additional Checks and Adjust ments in this section Service and Install Spark Plugs Fig 2 1 Inspect each plug individually for badly worn elec trodes glazed broken or blistered porcelains and re...

Page 268: ...rk plug wires in supports is impor tant to prevent cross firing 4 Tighten all ignition system connections 5 Replace or repair any wires that are frayed loose or damaged UsCORRECT LATERAL MISALIGNMENT...

Page 269: ...new points will provide no better service than the old points Refer to Section 6Y for an analysis of point burning or pitting Check point alignment fig 5 then adjust distri butor contact point gap to...

Page 270: ...he battery case will be placed under a severe strain To insure good contact the battery cables should be tight on the battery posts Oil battery terminal felt washer If the battery posts or cable termi...

Page 271: ...h automatic transmission pull through detent 4 Adjust accelerator rod to freely enter hole in carbu retor throttle lever NOTE Accelerator linkage is outlined in de tail in Section 6M 5 Connect acceler...

Page 272: ...f instrument panel 3 Loosen choke cable at carburetor bracket and adjust cable through the clip until the choke valve is wide open 4 Tighten cable clamp at carburetor bracket and check operation of ch...

Page 273: ...Valve Fig 15 0 1 Connect tachometer and vacuum gauge as for idle speed and mixture adjustment 2 Set parking brake start engine and adjust idle speed and mixture 3 Disconnect ventilation hose at valve...

Page 274: ...URE SIDE INLET HOLLEY 4150 CENTER INLET IDLE MIXTURE IDLE MIXTURE HOLLEY 4160 IDLE MIXTURE APPLICATION CARBURETOR IN LINE 153 90 194 120 230 140 250 155 V 8 283 195 210 327 275 300 325 350 350 295 396...

Page 275: ...as directed by manufacturer Excessive t n ti ft Fig 16 Cylinder Balance Test Fig 17 Testing Cranking Voltage resistance in primary circuit must be eliminated before continuing with test procedure Sec...

Page 276: ...r head and rocker arm cover may be sheared by bumping end of rocker arm cover rearward with palm of hand or a rubber mallet 2 With the engine running at idle back off valve rocker arm nut until the va...

Page 277: ...emoval and installation of en gine assemblies the removal installation and adjustment of some sub assemblies and replacement of some com ponents For service to all components and sub assem blies after...

Page 278: ...then remove transmission and clutch housing as a unit NOTE Support the transmission as the last mounting bolt is removed and as it is being pulled away from the engine to prevent damage to clutch dis...

Page 279: ...ntake or exhaust manifolds separate them by removing one bolt and two nuts at center of assembly Reassemble mani folds using a new gasket Tighten finger tight and torque to specifications after assemb...

Page 280: ...nger becoming tight in the bore of the lifter body to such an extent that the return spring can no longer push the plunger back up to working position Probable causes are a Excessive varnish or carbon...

Page 281: ...he compressor tool 8 Install spark plug using a new gasket and torque to specifications 9 Install and adjust valve mechanism as outlined CYLINDER HEAD ASSEMBLY Removal 1 Remove manifold assembly as ou...

Page 282: ...rolet engines The 5 1 2 length up for in line engines and the 4 side up for V8 engines 11 Remove oil pan and discard gaskets and seals Cfievel e 1 Remove enginfe from vehicle as outlined 2 Place engin...

Page 283: ...hen start engine and check for leaks Chevelie a Install oil pan and torque bolts to specifications b On vehicles equipped with automatic transmission install converter housing underpan c Install start...

Page 284: ...with new seal and torque to specifications Be sure cross seal tabs are in place and properly seated CRANKSHAFT PULLEY AND HUB Chevy II with L4 Engine Removal 1 Drain radiator and disconnect upper and...

Page 285: ...olts re move cover and gasket Installation 1 Clean gasket surfaces on block and crankcase front cover 2 Install centering Tool J 996 or Tool J 21742 in crankcase front cover seal fig 11L 3 Coat the ga...

Page 286: ...owly or attach an auxiliary starter switch and bump the engine over until the push rod is in the fully raised position CAUTION The primary distributor lead must be disconnected from the negative post...

Page 287: ...nstall fuel pump as outlined in Section 6M 7 Install grille as outlined in Section 13 8 Install crankcase front cover as outlined 9 Install radiator as outlined in Section 13 10 Install valve lifters...

Page 288: ...Replacement Chevrolet 1 Remove crossmember to mount bolts 2 Raise transmission to release weight from mount 3 Remove mount to transmission bolts then remove mount and spacer 4 Install spacer and new m...

Page 289: ...Main 6 32 Replacement 6 32 Torsional Damper 6 32 Removal 6 32 Installation 6 33 Crankcase Front Cover 6 33 Removal 6 33 Installation 6 33 Oil Seal Front Cover 6 34 Replacement 6 34 Timing Chain and or...

Page 290: ...will be necessary to remove mount from transmission before cross member can be removed 16 Remove engine transmission assembly from vehicle as a unit 17 Remove transmission and clutch Synchromesh Tran...

Page 291: ...stributor clamp and distributor then position distributor cap rearward clear of manifold 4 Remove coil 5 Remove manifold to head attaching bolts then re move manifold with carburetor on from engine an...

Page 292: ...ng to cylinder head and Installation 1 Clean gasket surfaces on cylinder head and rocker arm cover with degreaser then using a new gasket install rocker arm cover and torque bolts to specifications 2...

Page 293: ...number 6 firing position and crank shaft should be rotated one more revolution to reach the number 1 position b With the engine in the number 1 firing position as determined above adjust the following...

Page 294: ...ation 1 Install valve lifters NOTE Whenever new valve lifters are being installed coat foot of valve lifters with Molykote or its equivalent 2 Install intake manifold as outlined 3 Install and adjust...

Page 295: ...inder head bolts with sealing compound and install finger tight 5 Tighten cylinder head bolts a little at a time in the sequence shown on the torque sequence chart until the specified torque is reache...

Page 296: ...tions NOTE On 396 and 427 cu in engines start three 1 4 x 20 bolts into crankcase front cover before tightening any other pan bolts 7 Complete installation as follows Chevrolet and Camaro a Using a su...

Page 297: ...n back of seal To remove the upper half of the seal use a small hammer to tap a brass pin punch on one end of seal until it protrudes far enough to be removed with pliers fig 11V NOTE Always wipe cran...

Page 298: ...s not been re moved from the vehicle a 1 2 20 x 5 bolt and a 1 2 20 nut may be used in place of the bolt and nut of Tool J 21058 CAUTION Install bolt in crankshaft with suffi cient thread engagement m...

Page 299: ...ved pry old seal out of cover from the front with a large screw driver 2 Install new seal so that open end of the seal is toward the inside of cover and drive it into position with Tool J 995 on 283 3...

Page 300: ...e replaced remove sprocket using Tool J 5825 on 283 327 and 350 cu in engines fig 21V or Tool J 1619 on 396 and 427 cu in engines fig 22V Install new sprocket using Tool J 5590 on 283 327 and 350 cu i...

Page 301: ...e timing If improper valve opera tion is indicated measure the lift of each push rod in consecutive order and record the readings 1 Remove valve mechanism as outlined 2 Position indicator with ball so...

Page 302: ...w camshaft is installed CONVERTER BOLT AREA DEPRESSED SYNCHROMESH RING GEAR TRANS AUTOMATIC Fig 28V Flywheel Installation Typical coat camshaft lobes with Molykote or its equivalent 1 Lubricate camsha...

Page 303: ...t from mount 3 Remove mount to transmission bolts then remove mount and spacer on Chevrolets 4 Install new mount and spacer on Chevrolets on transmission 5 While lowering transmission align and start...

Page 304: ...ENGINE 6 39 CYLINDER HEAD TORQUE SEQUENCE L6 L4 V8 283 327 350 V8 396 427 INTAKE MANIFOLD TORQUE SEQUENCE FRONT V8 283 327 FRONT o o V8 396 427 Fig IT Torque Sequence CHEVROLET CHASSIS SERVICE MANUAL...

Page 305: ...J 6036 17 J 6880 18 J 5802 19 J 9534 20 J 9535 21 J 22144 22 J 8369 23 J 6098 24 J 0971 25 J 6978 26 J 22197 27 J 21058 28 J 1619 29 J 5825 30 J 8105 31 J 5590 32 J 0966 33 J 21742 34 J 22102 35 J 83...

Page 306: ...cooling level is too high All passenger car cooling systems are pressurized with a pressure cap which permits safe engine operation at cooling temperatures of up to 247 F When the radiator cap is rem...

Page 307: ...e to the normal flow This action causes the water to get behind the corrosion deposits and force them out Radiator 1 Remove the upper and lower radiator hoses and re place the radiator cap 2 Attach a...

Page 308: ...ight out of the block first to avoid damage to impeller Installation 1 Install pump assembly on cylinder block and tighten bolts securely Use on new pump to block gasket s 2 Install pump pulley and fa...

Page 309: ...ROCEDURES Preliminary Checks 1 Thoroughly warm up engine If the engine is cold allow to run for at least 15 minutes 2 Inspect torque of carburetor to intake manifold bolts and intake manifold to cylin...

Page 310: ...LE SPEED IDLE MIXTURE SIDE INLET HOLLEY 4150 CENTER INLET IDLE MIXTURE IDLE MIXTURE IDLE SPEED HOLLEY 4 1 6 0 IDLE MIXTURE IDLE SPEED APPLICATION CARBURETOR U IN LINE 153 90 194 120 230 140 250 155 V...

Page 311: ...Holley With fast idle lever on high step of cam and choke valve open engine warm set fast idle to give specified engine rpm Adjust sejrew on Rochester 4MV and bend fast idle lever pn Holley Choke Adju...

Page 312: ...les slightly and hand operate secondary throttle This assures a stabilized secondary fuel level Additional Adjustments The following adjustments may be made without re moving the carburetor from the e...

Page 313: ...Remove inlet fuel filter nut from carburetor with a 1 box wrench or socket 3 Remove filter element and spring fig 4c Fig 5C Choke Coil L6 Engine 4 Fig 4C Fuel Filter Check element for restriction by b...

Page 314: ...hoke coil shield installed Disconnect choke rod upper end and lower choke coil shield over choke rod and install over choke coil Move shield to best fit along manifold and con nect upper end of choke...

Page 315: ...2 000 miles the flame ar resters should be removed cleaned in solvent and blown dry with compressed air An oil wetted polyurethane element air cleaner fig 1A is standard equipment on In Line engines T...

Page 316: ...ss oil NOTE Never shake swing or wring the ele me nt to remove excess oil or solvent as this may tear the polyurethane material Instead squeeze the excess from the element 6 Install element on screen...

Page 317: ...plug all openings except air cleaner inlet 2 Install air cleaner using Tool J 7825 in place of the wing nut Screw Tool J 7825 onto the stud until it seals tightly against the air cleaner cover Rotate...

Page 318: ...eccentric located on the engine camshaft On in line engines the eccentric actuates the rocker arm On V 8 engines a push rod located be tween the camshaft eccentric and fuel pump actuates the pump roc...

Page 319: ...ing withint specified limits as follows a Attach a fuel pump pressure test gauge to dis connect end of pump to carburetor pipe b Run engine at approximately 450 1 000 rpm on gasoline in carburetor bow...

Page 320: ...ENGINE FUEL 6M 12 SPECIAL TOOLS 1137 J 4552 J 5496 J 7825 1 5 J 6058A BENDING TOOLS J 5197 J 6556 J 9789 J 8328 Fig lT Engine Fuel Special Tools CHEVROLET CHASSIS SERVICE MANUAL...

Page 321: ...ack flow can occur even under normal operating conditions When properly installed and maintained the A I R System will keep exhaust emissions well below require ments However if any A I R component or...

Page 322: ...COVER A J HTEXHAUST wBBE TUBES SB 1 INTAKE J H T U B E Check all hose and tube connections Check all tube and hose routing Interference may cause wear If a leak is suspected on the pressure side of th...

Page 323: ...ted A pump that had become inoperative and had shown indications of having exhaust gases in the pump would indicate check valve failure Orally blow through the check valve toward air manifold then att...

Page 324: ...of the Air Injection Reactor System oper ate the engine with the pump drive belt removed IN LINE INJECTION si AIR AAANIFOLD ASSEMBLY AIR MANIFOLD ASSEMBLY S jk VALVE V 8 ff yi INJECTION TUBE Fig 5 Air...

Page 325: ...e pressure setting plugs are color coded To remove the pressure setting plug carefully unlock legs from inside surface of relief valve with a small screw driver To install the pressure setting plug ca...

Page 326: ...tes and all the negative plates into groups The elements are connected in series electrically by connectors that pass directly through the case partitions between cells The battery top is a one piece...

Page 327: ...rvicing ACTIVATING DRY CHARGED BATTERIES A dry charge Battery is activated by filling each cell with electrolyte which is a dilute solution of sulfuric VENT WELL SEAL SPLIT VENT Fig 3b Vent Well Const...

Page 328: ...e level in all six cells An alternate method of checking the electrolyte level is to remove the vent plug and visually observe the electro lyte level in the vent well The bottom of the vent well featu...

Page 329: ...at which charging current is sup plied One is the Slow Charge method the second is the Fast Charge method and the third is the Emergency Boost Charge method Before recharging a Battery by any method t...

Page 330: ...to a dis charged condition the acid leaves the solution and enters the plates causing a decrease in specific gravity of electrolyte An indication of the concentration of the electrolyte is obtained w...

Page 331: ...enly until snug 60 80 in lbs Do not draw down tight enough to distort or crack the case or cover Be sure the cables are in good condition and the terminal clamps are clean and tight Make sure the grou...

Page 332: ...e shaft of the rotor Six rectifier diodes are mounted in the slip ring end frame and are joined to the stator windings at three internally located terminals Diodes are mounted in heat sinks to provide...

Page 333: ...ly static voltage regulating unit in combination with a conventional vibrating type field relay The transistor is an electrical device which limits the generator voltage to a preset value by controlli...

Page 334: ...e link is installed as a molded splice in the generator and forward lamp harness and is serviced by splicing in a new 20 gage wire as required The ammeter circuit on all models is protected by two ora...

Page 335: ...empting to make the re quired test connections at the voltage regulator It is advisable to remove the regulator from its mounting location to perform the necessary con nections at the regulator for th...

Page 336: ...utes of warm up then cycle regulator voltage control by disconnecting and re connecting regulator connector and read voltage If voltage is 13 5 to 15 2 the regulator is okay If voltage is not within 1...

Page 337: ...ined under Service Operations INDICATOR LAMP INITIAL FIELD EXCITATION CIRCUIT TESTS Fig 10c On standard models the indicator lamp circuit provides initial field excitation causing lamp to glow The lig...

Page 338: ...ff positive diode shorted see Diode test FIELD CIRCUIT RESISTANCE WIRE CHECKS The resistance wire is an integral part of the ignition harness However the resistance wire is not solderable it must be s...

Page 339: ...rging system harness need be checked for continuity by use of an ohmmeter or a test ligjit 12 Volt Connect the test so the wire in question is in series in the test circuit SERVICE OPERATIONS Service...

Page 340: ...y and washer on shaft and start the nut 4 Use the socket and adapter with a torque wrench and tighten nut to 50 ft lbs torque BRUSH REPLACEMENT 6 2 Delcotron 1 Remove two nuts retaining the blade conn...

Page 341: ...iscolored condition of the contacts is normal after a relatively short period of operation Fig 19c Checking Field Relay Point Opening REMOVAL AND INSTALLATION To remove the regulator assembly disconne...

Page 342: ...ing is checked as il are within specifications the relay will operate lustrated in Figure 19c If adjustment is necessary satisfactorily even though the air gap may not be carefully bend the armature s...

Page 343: ...ne as a ballast between the coil negative terminal and ground while the other resistance wire provides a voltage drop for the engine run circuit and is by passed at cranking The other units in the sys...

Page 344: ...ill not be damaged by the tachometer that is to be used IGNITION COIL CHECK BREAKERLESS The ignition coil primary can be checked for an open PULSE AMPLIFIER IGN SWITCH WIRE IGN TERMINAL E3 IJU 12 WHIT...

Page 345: ...d with a spring gauge The scale should be hooked to the breaker lever and the pull exerted at 90 degrees to the breaker lever as shown in Figure 5i The reading should be taken just as the points sepa...

Page 346: ...NECESSARY Fig 8i Inaccurate Gauging of Rough Points SETTING DWELL ANGLE Four and Six Cylinder Engine Distributors The point opening of new points can be checked with a feeler gauge but the use of a fe...

Page 347: ...ench into the adjusting screw head fig Hi WINDOW r HEX TYPE WRENCH ADJUSTING SCREW Fig lli Adjusting Dwell Angle 1 Preferred Method Turn the adjusting screw until the specified dwell angle is obtained...

Page 348: ...s remove ignition shield from over distributor and coil One bolt is accessible from top of shield the other two are at rear of shield facing firewall 2 Release the distributor cap hold down screws re...

Page 349: ...tributor condition and indicate parts replacement which may be necessary Check the area on the breaker plate just beneath the contact points A smudgy line indicates that oil or crankcase vapors have b...

Page 350: ...distributor cap and sparkplug wires for damage and replace if necessary ASSEMBLY Four and Six Cylinder Engine Refer to Figure 12i for Exploded View of Distributor 1 Replace cam assembly to mainshaft N...

Page 351: ...at the spark plug wires be installed in their proper location in the supports 4 Time ignition as previously described under Tune Up in Section 6 INSTALLATION ENGINE DISTURBED ALL MODELS 1 Locate No 1...

Page 352: ...pickup assembly only it will be necessary to perform only Steps 3 4 5 7 8 9 and 12 of the service procedure listed below 1 Remove screws securing rotor and remove rotor 2 Remove centrifugal weight sp...

Page 353: ...NSISTOR TR3 COMPONENT CHECKS Figs 7 and 18i With the two transistors separated from the assembly an ohmmeter may be used to check the transistors and components on the panel board for defects An ohmme...

Page 354: ...ansistors are mounted The silicone grease which is available commercially conducts heat and thereby pro vides better cooling IGNITION PULSE AMPLIFIER R 5 C 3 Ju MAGNETIC PULSE DISTRIBUTOR IGNITION SWI...

Page 355: ...witch and Connector Unplugged 8 Remove ignition switch bezel nut using Tool J 7607 and push switch rearward from panel opening 9 Disconnect wiring connector from rear of switch 10 To install reverse r...

Page 356: ...bend the center electrode which and tighten to specifications If torque wrench is not extends through the porcelain center Always available tighten plugs finger tight and 1 2 turn more make adjustment...

Page 357: ...d switch operates the overrunning clutch drive by means of a linkage to the shaft lever The V 8 wiring harness differs from the in line engine in that the ignition lead to the coil from the switch is...

Page 358: ...n the switch S terminal of the solenoid and ground with the starting switch closed CAUTION If the solenoid feels warm allow to cool before checking If the voltage is less than 7 7 volts check for ex c...

Page 359: ...OOLS J 7607 IGNITION SWITCH NUT REMOVER J 9717 2 SUPPORT TOOL J 9717 1 PRESS TOOL J 9600 2 SHOULDERED INSTALLER J 21501 PULLY ADAPTER J 5184 CHECKING SCALE J 21600 HARNESS ADAPTER Fig 4s Specia Tools...

Page 360: ...onger bearing used with the straight diaphragm will cause inability to obtain free pedal travel especially as the clutch wears resulting in slippage and rapid wear DO NOT INTERCHANGE The clutch is ope...

Page 361: ...oper clearance Readjust if necessary Chevy II Linkage Adjustment Fig 3 L 4 L 6 Models 1 Loosen locknut A and lengthen or shorten push rod in swivel as required by turning with wrench on ma chined flat...

Page 362: ...ngine speed should drop noticeably then accelerate with vehicle If clutch is bad the engine speed will in crease NOTE Do not repeat more than once or clutch will overheat NUTC NUTC SPACER F SPACER F R...

Page 363: ...nside of throwout bear ing collar and the throwout fork groove with a light coat of graphite grease fig 4 On Corvette models use Moly Grease 7 Install clutch fork and dust boot into clutch housing and...

Page 364: ...CLUTCH AND TRANSMISSIONS 7 5 CHEVY II Fig 6 Lower Linkage Details Chevrolet Chevelle Chevy II CHEVROLET CHASSIS SERVICE MANUAL...

Page 365: ...a single row of rollers at both ends while thrust is taken on thrust washers located between the ends of the gear and the thrust bosses in the case Ah anti rattle plate assembly at the front of the c...

Page 366: ...K and secure with retainer 6 With Lever C against Locating Pin attach Swivel to lever and secure with retainer iRun Nut G against Swivel then tighten Nut E against Swivel 7 Remove Locating Pin and ch...

Page 367: ...not to damage seals Install both shift forks to shifter shaft assemblies lifting up on detent cam to allow forks to fully seat into position 4 Install outer shifter levers flat washers lock wash ers...

Page 368: ...acket d Remove the two bolts from mount pad to trans mission case and remove rubber mount cushion and exhaust pipe yoke 15 Disconnect transmission linkage by removing the shift levers at the transmiss...

Page 369: ...the out put shaft rear oil seal the control shaft lever and the speedometer driven gear may be accomplished without removing the overdrive from the vehicle as discussed in the following paragraphs GO...

Page 370: ...er wire between negative terminal of battery and mounting flange of solenoid Connect a second jumper wire be ARMATURE SPRING PQST BEND TO ADJUST CLOSING VOLTAGE Fig 3B Adjusting Relay Closing Voltage...

Page 371: ...3 16 before the throttle lever touches its stop Occasionally the large nuts which clamp the switch through the switch bracket are tightened sufficiently to bend the switch shank thus pre venting free...

Page 372: ...etween the kickdown and governor switches and replace if necessary 2 Does not release a Remove the connection to the KD terminal of the relay If this release overdrive look for a grounded control circ...

Page 373: ...clutch hub clutch sleeve two clutch key springs and three energizer clutch keys and are retained as an assembly on the main shaft by a snap ring The transmission may be used as an aid in deceleration...

Page 374: ...tion 1 Install new side cover gasket to transmission case install cover and secure with lock washers and cap screws NOTE The two rear side cover to case at taching bolts have a special oil sealing spl...

Page 375: ...lever to the rear of the transmis sion cover controls first and second gears while the lever to the front controls third and fourth gears All four forward gears are fully synchronized The trans missi...

Page 376: ...en lock and cut off excess cable 5 Reverse Steps 1 2 and 3 to install Figure 3M shows the adjustment and lubrication proce dure for the mechanism This Figure applies to both models of lever assemblies...

Page 377: ...ift Linkage Camaro Corvette Typical HANDLE BUSHING 3 REQ D KNOB CABLE TUBING CABLE ASSEMBLY LEVER LEVER ASSEMBLY LUBE I D OF LEVER WITH 20 30 WGT MOTOR OIL ANTI RATTLE O RING SET SCREW COAT WITH LUBRI...

Page 378: ...cement is required because of damage 1 2 DETENT CAM DETENT SPRING 3 4 DETENT CAM 1 2 SHIFTER SHAFT 1 2 SHIFT FORK 3 4 SHIFT FORK DETENT CAM 3 4 SHIFTER SHAFT RETAINER RING DETENT CAM PIVOT PIN 3 Remov...

Page 379: ...inkage Adjustment 7 21 Speedometer Driven Gear and Oil Seal See Muncie 4 Speed Side Cover 7 22 Page Removal 7 22 Disassembly 7 22 Assembly 7 22 Installation 7 22 Extension Oil Seal See Muncie 4 Speed...

Page 380: ...tral detent position 2 Move Lower Control Lever A to neutral detent po sition and insert Locating Gauge B into Control Lever Bracket Assembly 3 Install Reverse Control Rod G with retainer on Lever X 4...

Page 381: ...N ii K 3 A 1 2 DETENT CAM PIVOT PIN DETENT SPRING 3 4 DETENT CAM 3 4 SHIFT FORK 1 2 SHIFTER SHAFT ASSY REVERSE SHIFTER SHAFT ASSY 3 4 SHIFTER SHAFT ASSY DETENT SPRING RETAINER BALL UNDERNEATH 1 2 SHI...

Page 382: ...rglide Transmission is a single case aluminum unit When the manual control is placed in the drive po sition the transmission automatically shifts to low gear for initial vehicle movement As the car ga...

Page 383: ...elle Models To gain clearance between underbody and transmission it may be necessary to remove rear mount bolts from crossmember and move transmission slightly toward passenger side of vehicle 4 Loose...

Page 384: ...of operation Floor Shift Linkage Chevrolet Linkage Adjustment Fig 6PG 1 Loosely assemble Nuts A and B on Lower Rod C 2 Set Transmission Lever D in drive position NOTE Obtain drive position by moving...

Page 385: ...E B LEVER B VIEW B BRACKET ROD C VIEW A Fig 3PG Chevelle Shift Linkage Adjustments BUSHING VIEW A NUT D ROD C VIEWD 1 00MIN NOTE DIMENSION MUST BE MAINTAINED WITH TRANS IN NEUTRAL POSITION TUBE LEVER...

Page 386: ...See View B 4 Apply load in direction of Arrow H on Actuating Lever F until Pawl Rod comes in contact with De tent K at Contact Point G See View B 5 Place 090 Spacer between Nut E and Swivel run Nut E...

Page 387: ...ITION CONTACT POINT Z v ACTUATING 4 VIEW A LEVER G ACTUATING LEVER F LOAD G 1 ROD QS yYi LOAD H NUT D tl SPACER Hh 09 SWIVEL VIEW A POINT OF V CONTACT G A DETENT K H VUULPAWL VIEW B y DETENT K Fig 7PG...

Page 388: ...glide Control Lever and Bracket Assembly Powerglide control lever and bracket assembly is a straight line shift type mounted to the floor of the body rather than the transmission extension as in the p...

Page 389: ...crossmember and slide rearward 7 Remove converter underpan scribe flywheel con verter relationship for assembly then remove the flywheel to converter attaching bolts NOTE The light side of the convert...

Page 390: ...the underbody to prevent upward travel of the carrier when the car rier front support is disconnected 5 Disconnect the differential carrier front support from its frame bracket by removing the nut on...

Page 391: ...diagnosis may be accomplished This will result in a savings of time not only to the service man but to the customer as well WARMING UP TRANSMISSION Before attempting to check and or correct any com p...

Page 392: ...embly or pump bolt sealing washers BASIC PRESSURE CHECKS Four basic pressure checks are used for diagnosis and operational checks for the Aluminum Powerglide trans mission All checks should be made on...

Page 393: ...50 Pass L 6 250 Taxi Police V 8 283 V 8 327 2BBL Camaro V 8 327 427 V 8 396 V 8 327 W RPO K 19 V 8 350 Wide Open Throttle Upshift psi 93 104 96 112 91 105 96 112 90 105 91 107 104 119 104 119 99 113 9...

Page 394: ...F70 14 Tire Up 14 8 18 3 55 3 67 4 68 9 76 9 Down 13 5 17 2 16 7 20 8 64 1 72 6 Chevy II Models MPH Engine Throttle Position Closed Detent Touch Full Detent L194 Base M35 3 08 Axle 6 95 14 Tire Up 13...

Page 395: ...ear side of the stator vanes in a clockwise direction Since the stator is now impeding the smooth flow of oil its roller clutch releases and it revolves freely on its shaft Once the stator becomes ina...

Page 396: ...inkage will prevent the selector lever from moving beyond both the neutral detent and the drive detent unless the lever is lifted to pass over the mechanical stop in the steering column See schematic...

Page 397: ...ottom pan and Strainer 2 Compress regulator boost valve bushing against pressure regulator spring and remove snap ring using J 5403 pliers 3 Remove regulator boost valve bushing and valve 4 Remove pre...

Page 398: ...s readjust if required LEVER E LEVER D ACTUATING LEVER G LOAD Y SWIVEL J NUT A GROMMET Fig 2T Gearshift Controls console Typical Installation Installation of the pressure regulator valve is the re ver...

Page 399: ...ottom pan gasket REAR SEAL Removal 1 Remove propeller shaft 2 Pry seal out with screw driver Installation 1 Using Tool J 5154 or J 21359 install new seal 2 Re install propeller shaft OTHER SERVICE WIT...

Page 400: ...AGE Manual linkage adjustment and the associated neutral safety switch are important from a safety standpoint The neutral safety switch should be adjusted so that the engine will start in the Park and...

Page 401: ...sure gauge and engine tachome ter should be connected and the oil pressures should check as follows 1 Pressures indicated below are at 0 output speed with the vacuum modulator tube disconnected and wi...

Page 402: ...CLUTCH AND TRANSMISSIONS 7 43 SPECIAL TOOLS 1 J 1522 Pilot Bearing Driver Fig 3T Clutch Special Tools 2 J 5824 Clutch Pilot Tool 3 J 1448 Pilot Bearing Puller CHEVROLET CHASSIS SERVICE MANUAL...

Page 403: ...ool 5 J 22246 Countergear Loading Tool 6 J 5778 Extension Housing Bushing Remover and Installer 7 J 5154 Extension Housing Seal Installer 8 J 5814 15 9 J 1453 01 J 358 1 10 J 4653 11 J 5590 12 J 7785...

Page 404: ...ring Compressor Planet Pinion Assembly Tool Set Reverse Piston Spring Compressor Transmission Case Rear Bushing Remover and Installer and Rear Pump Bushing Remover 15 J 7079 16 J 6582 17 J 9543 18 J 5...

Page 405: ...ge and Hose Rear Band Apply Fixture Rear Band Apply Pin Gear Unit Assembly Holding Tool Part of Above Holding Tool 5 J 5384 16 J 21465 01 17 J 21465 5 18 J 21465 3 19 J 21465 2 20 J 21465 1 21 J 21465...

Page 406: ...o Gear Remover Puller Accumulator Piston Installer Converter Pressure Check Fixture Seal Protector Forward Direct Clutch Inner 9 J 21363 10 J 21409 11 J 21664 12 J 4670 13 J 8059 14 J 5586 15 J 5403 1...

Page 407: ...fig 1 use a 24 gallon capacity approx fuel tank mounted between the frame rails behind the rear axle The fuel tanks are held in place by two straps attached individually to the underbody at each end...

Page 408: ...See Figure 2 2 Insert a small pipe nipple slightly larger O D than the hose I D into the opposite end of hose 3 Insert the nipple end of the siphon hose into the fuel tank filler neck with the natura...

Page 409: ...straps and lower tank carefully 7 To install reverse the removal procedure Removal and Installation Station Wagon 1 Drain fuel tank 2 Raise vehicle 3 Remove gas tank shield at the back of the left re...

Page 410: ...e tank and the other at the vent pipe which is secured to the underbody A rubber grommet around the vent pipe acts as a seal to prevent gasoline fumes from entering the passenger compartment IMPORTANT...

Page 411: ...orrect alignment frequently causes annoying rattles due to in correct clearances MUFFLER ASSEMBLY Remove and Replace 1 Remove U bolt clamp at center mounting 2 Remove U bolt clamp at forward end of mu...

Page 412: ...FUEL TANK AND EXHAUST SYSTEMS 8 6 1 1 S T G E A R STD TRANS CONTACT OF EXHAUST PIPE TO ENGINE PAN RAIL IS PERMISSIBLE VIEW E Fig 6 Single Exhaust Systems CHEVROLET CHASSIS SERVICE MANUAL...

Page 413: ...FUEL TANK AND EXHAUST SYSTEMS 8 7 1 I kSSIS SERVICE...

Page 414: ...Refer to the recommended draining procedures previously outlined under Chevrolet Models in this section Removal and Installation Sedan Models 1 Raise vehicle 2 Drain fuel tank 3 Disconnect fuel picku...

Page 415: ...ger compartment IMPORTANT It is important to note that the gas tank is not vented at the cap therefore it is necessary to be assured that the vent line is free from dirt etc and that the gas tank vent...

Page 416: ...FUEL TANK AND EXHAUST SYSTEMS 8 10 Fig 11 Gauge Unit Assembly Fig 12 Fuel Tank Gauge Unit Removal CHEVROLET CHASSIS SERVICE...

Page 417: ...s are suspended on brackets with insulators for rattle free operation The mufflers are a seam rolled construction with spot welded baffles with a capacity for muffling the exhaust and at the same time...

Page 418: ...replaced it will be necessary to replace both the exhaust pipe and muffler with service replacement parts The right exhaust crossover pipe may be replaced without replacing the entire system as follow...

Page 419: ...nto the sys tem The tank can be drained by siphoning at the filler neck or by removing the gauge sending unit and siphon ing at the tank opening CAUTION Care should be exercised to avoid denting or pu...

Page 420: ...the carburetor or fuel pump disassembly the lines should be disconnected and blown out Check the fuel tank strainer for damage or omission Fuel lines are of 5 16 di ameter tubing for regular installat...

Page 421: ...FUEL TANK AND EXHAUST SYSTEMS 8 15 V 8 ROUTING L 4 L 6 ROUTING Fig 17 Fuel Lines Fig 18 Fuel Tank Vent Line CHEVROLET CHASSIS SERVICE...

Page 422: ...two exhaust pipes mufflers tail pipes with resonators and attaching hardware The assemblies are secured to the engine at the ex haust manifolds to the center mounting at the muffler location and adja...

Page 423: ...e NOTE If bracket mounting insulators tire carcass mountings are fatigued replace to in sure a secure exhaust system EXHAUST PIPE Replacement On V 8 engine exhaust models if the left exhaust pipe has...

Page 424: ...her anti squeak pad cemented on the support at the front of the tank The fuel tanks are equipped with a gas gauge metering unit a fuel pickup fuel strainer and vent line If it be comes necessary the t...

Page 425: ...Place hoses and wires to one side and position anti squeak pads to the crossmember END OF HOSE FLUSH TO Va INCH BACK FROM EDGE OF BUMPERETTE Fig 24 Gas Tank Filler Neck Vent Hose cemented to the suppo...

Page 426: ...reen on the end of the pipe 5 Clean strainer screen by blowing out with com pressed air 6 Reverse procedure to install Replacement 36 Gallon Tank 1 Remove cover 2 Follow Steps 2 thru 6 as outlined und...

Page 427: ...FUEL TANK AND EXHAUST SYSTEMS 8 21 Fig 27 Gasoline Tank 36 Gallon Wiring CHEVROLET CHASSIS SERVICE MANUAL...

Page 428: ...Fig 28 Corvette Fuel Lines 20 Gallon Tank...

Page 429: ...FUEL TANK AND EXHAUST SYSTEMS 8 23 CHEVROLET CHASSIS saevia...

Page 430: ...are mounted outboard of the frame side rails at the rocker panel level and completely replaces the regular dual assemblies Flow characteristics are improved and back pressures reduced by the more dir...

Page 431: ...ountings are fatigued replace to in sure a secure exhaust system 7 In the event the tail pipe bezel has been damaged and replacement is required remove three screws and replace the bezel i SIDE MOUNTE...

Page 432: ...r bracket and retaining nut to the exhaust pipe retaining nuts rear bracket 7 Position molding retainer and cover to sill and in 6 Insert rear bracket bolt in frame opening position stall retaining sc...

Page 433: ...mounted between the frame rails behind the rear axle fig 32 All fuel tanks are vented through an anti surge type filler cap assembly consisting of cap and handle The carrying straps hook through a do...

Page 434: ...Remove cam lock using special Tool J 8950 3 Remove meter unit and rubber gasket CAUTION Carefully remove unit so as not to damage screen on end of pipe 4 Clean screen by blowing out with compressed a...

Page 435: ...FUEL TANK AND EXHAUST SYSTEMS 8 29 Fig 34 Fuel Tank Meter Assembly CHEVROUET CHASSIS SERVICE MANUAL...

Page 436: ...FUEL TANK AND EXHAUST SYSTEMS 8 30 Fig 35 Fuel Line Routing CHEVROLET CHASSIS SERVICE MANUAL...

Page 437: ...ly and insulator attached to an existing underbody bracket COMPONENT PART REPLACEMENT EXHAUST PIPE Replacement 1 Loosen U bolt clamp at rear exhaust pipe connection 2 Remove exhaust pipe to manifold a...

Page 438: ...checked Check position of hanger so that inter plates are parallel 4 Tighten nuts at U bolt clamp then secure rear tail pipe clamp RESONATOR Replacement 1 Cut exhaust pipe at resonator inlet 2 Loosen...

Page 439: ...FUEL TANK AND EXHAUST SYSTEMS 8 33 MUFFLER TAIL PIPE ASSY Fig 37 Dual Exhaust System CHEVROLET CHASSIS SERVICE MANUAL...

Page 440: ...D EXHAUST SYSTEMS 8 34 SPECIAL TOOLS Fig 38 Special Tools 1 J 8950 Fuel Tank Gauge Unit Spanner 2 J 7777 Fuel Line Clip Installer 3 J 22554 Fuel Tank Gauge Unit Spanner Chevrolet CHEVROLET CHASSIS SER...

Page 441: ...ngs The steering linkage is of the relay type and extended interval lubrication design with the pitman arm connected to one end of the relay rod The other end of the relay rod is connected to an idler...

Page 442: ...nut and turn the adjuster screw a few turns in a counter clockwise direction fig 3 This removes the load Fig 2 Removing Pitman Arm imposed on the worm bearings by the close meshing of rack and sector...

Page 443: ...of worm bearings there is probably damage in the bearings due to severe impact or to improper adjustment and the gear must be disassembled for replacement of damaged parts 6 After proper adjustment o...

Page 444: ...the horizontal centerline of the steering wheel fig 5 If the horizontal spokes are over 1 1 8 inches from the horizontal position the wheel should be removed and centered See steering wheel removal i...

Page 445: ...t and washer 6 Using Tool J 2927 install centering adapter on steering shaft thread puller anchor screws into threaded holes provided in hub assembly Turn center bolt of tool clockwise to remove hub a...

Page 446: ...g wheel and hub assembly in position and secure to column with washer and nut 4 Position spacer on steering wheel 5 Position lock knob on steering wheel 6 Install lock screw through lock knob turn int...

Page 447: ...s shown in Figure 13 On Corvette models the covers are re moved in the engine compartment side Also on Corvette models remove screws securing escutcheon fig 14 to instrument panel 5 Disconnect Steerin...

Page 448: ...rom vehicle Installation 1 Lift steering column enough to provide clearance and loosely install steering coupling on steering gear shaft Be sure column is supported in its normal mounted position at a...

Page 449: ...m and shaft and remove arm using Tool J 6632 3 Remove nuts washers and bolts securing steering gear to frame and remove gear from vehicle Installation NOTE Steering assembly alignment must be checked...

Page 450: ...nd assembly procedures for Standard Corvette column 5 Telescopic wheel option The upper end and steering shaft of this column is specially designed to ac commodate the optional telescoping steering wh...

Page 451: ...and washers securing inner cover outer cover and seal to dash panel and remove covers 11 Chevy U only Fig 21 a Remove staple from collar and loosen collar b Remove screws securing clamp and loosen cl...

Page 452: ...screws securing support assembly and seal to engine side of dash panel 14 Support column and remove screws nuts and bolts securing instrument panel mounting bracket to un derside of instrument panel...

Page 453: ...ush hazard warning switch in unscrew and remove knob 5 Drive out shift control lever retaining pin and re move shift lever 6 Remove C retaining ring from upper steering shaft using snap ring remover T...

Page 454: ...to the column 17 Remove reinforcing ring adapter with bearing first and reverse shift lever and spacer from lower end 18 Withdraw shift tube assembly from lower end 19 Remove the lower bowl bearing f...

Page 455: ...er end of the jacket Attach the back up lamp switch loosely to the jacket using the same nuts removed during disassembly Install these nuts loosely switch will be tightened to the jacket when column i...

Page 456: ...ntional or Powerglide floor shift controls 1 Unsnap and remove wiring protector and wiring clip CAUTION Secure column in bench vise for service one of two ways shown in Figure 26 Clamping column in vi...

Page 457: ...Attach the back up lamp neutral start switch if so equipped to the jacket using the same nuts removed during disassembly Install these nuts loosely the switch must be adjusted after column is installe...

Page 458: ...11 9 7 5 3 34 V33 29 27 26 36 35 32 3130 28 46 45 44 43 42 Fig 37 Tilt Steering Column Exploded View 1 Cover 2 Steering Wheel Nut 3 Nut 4 Seat 5 Race 6 Screw 7 Turn Signal Switch 8 Bearing Assembly 9...

Page 459: ...tly check position of column in vise jaws to insure column is not working free of jawsT 2 Clamp column in a bench vise as shown in Figure 26 3 Slide upper bearing preload spring and cancelling cam off...

Page 460: ...ing fig 41 d Turn upper shaft 90 from center line of lower shaft and remove shaft e Rotate centering spheres and remove spheres and wave washer from lower shaft 18 Remove screws securing the support a...

Page 461: ...he hous ing using release lever pivot remover Tool J 22635 fig 45 View A b Hold the shoe springs in compression by rocking lock shoes in with a wedge to relieve the load on the shoe release lever driv...

Page 462: ...n of shift tube using shift tube installer Tool J 22549 as shown in Figure 46 Do not hammer or force tube when in stalling in jacket 12 Pull up on bowl to compress wave washer and install thrust washe...

Page 463: ...rance kit ring section then screw inner ring section back in 1 8 to 1 4 turn fig 36 26 Tighten bearing locknut installed in Step 24 above until the torque required to rotate the steering shaft with th...

Page 464: ...h and upper bearing housing from cover 9 Carefully slide steering shaft assembly out of lower end of mast jacket 10 If necessary remove lower bearing assembly from lower end of mast jacket and discard...

Page 465: ...bearing housing and turn signal switch into cover and secure entire assembly to mast jacket upper flange with three signal switch mounting screws as shown in Figure 51 Feed turn signal switch wires th...

Page 466: ...g preload spring and cancelling cam from end of shaft 3 Remove turn signal lever retaining screw and re move lever Push hazard warning knob in unscrew and remove knob 4 Remove upper retaining ring fro...

Page 467: ...cket 7 Install bearing retainer over lower end of shaft and lower end of jacket Secure retainer with three screws 8 Install flange and flange bolt on lower end of steering shaft 9 Feed wires of turn s...

Page 468: ...on in strument panel column mounting bracket and place bracket in correct position on underside of instru 3 4 Fig 59 Instrument Panel Mounting Bracket Chevy ment panel Loosely install bracket using b...

Page 469: ...crews 13 On Chevrolet and CheveUe models with column mounted powerglide controls secure transmission shift indicator pointer into position with set screw fig 15 14 Chevrolet only fig 19 a Secure seal...

Page 470: ...e outer ball stud tap on steering arm at tie rod end with a hammer while using a heavy hammer or similar tool as a backing Fig 63 If necessary pull downward on tie rod to remove from steering arm 3 Re...

Page 471: ...ring damper from relay rod as outlined under Steering Damper Removal Remove anchor bracket from relay rod by disconnecting two mount ing bolts 2 Remove inner ends of tie rods from relay rod as describ...

Page 472: ...collision or other damage it becomes nec essary to remove and replace either steering arm pro ceed as follows Removal 1 Remove tie rod from steering arm as outlined in this section 2 Remove front whee...

Page 473: ...te valve housing The valve is an open center rotary type three way valve The spool is held in neutral position by means of a torsion bar The spool is attached by means of the stub shaft to one end of...

Page 474: ...at rear of manual for correct torque values 8 Install horn button Connect steering column harness at wiring connector plug Chevy II and Corvette The steering gear used with power steering is adjusted...

Page 475: ...specifications it may be safely assumed that the external hoses connections valve and adapter or steering gear is at fault NOTE If pump proves faulty in test number two test should be repeated after...

Page 476: ...nt and Repairs In addition disconnect pressure and return hoses from the steering gear housing Cap both hoses and steering gear outlets to prevent foreign material from entering the system After servi...

Page 477: ...ntrol valve from the vehicle Installation 1 Install the control valve on the vehicle by reversing the removal procedure 2 Reconnect the hydraulic lines fill the system with fluid and bleed out air usi...

Page 478: ...STEERING 9 38 CHEVROLET CHEVELLE CAMARO Fig 71 Power Steering Hose Installation CHEVROLET CHASSIS SERVICE MANUAL...

Page 479: ...1 Reassemble the piston rod seal components by re versing the disassembly procedure Apply a thin coat of Lubriplate or equivalent on the inner sur faces of the seal and scraper before assembly 2 Rever...

Page 480: ...t Tube Installer 11 J 22551 Shift Tube Remover 12 J 5421 Thermometer 13 J 22635 Locking Shoe Guide Pin and Release Lever Pin Remover and Installer 14 J 7754 Inch Pound Torque Wrench 15 J 22569 Snap Ri...

Page 481: ...ing and Recommended Tire Inflation Pres sures Table see Specifications Optional Oversize and 8 Ply Rating Tires Chevrolet and Chevelle Only Oversize or 8 ply rating tires are not necessary on passenge...

Page 482: ...re one end of each tread block is worn more than the other The end that wears is the one that first grips the road when the brakes are applied Heel and toe wear is less noticeable onsrear tires than o...

Page 483: ...e drums Fig 4 Cornering Wear out of round brakes out of adjustment or other me chanical conditions The remedy in each case consists of locating the mechanical defect and correcting it Cornering Since...

Page 484: ...however most pronounced at speeds of approx imately twenty or thirty miles per hour The tires may be further checked by driving the ear over smooth pavement with the tires at normal pressure and again...

Page 485: ...s installed on the wheels Run Out W OTire The wheels should not run out wobble more than 1 16 as measured on the side of the rim at the base of the tire Excessive run out is the result of a bent wheel...

Page 486: ...h for the patch Follow the manufacturer1 s instructions for appli cation of the special cement and self vulcanizing cold patch Pressure Gun Method Several types of pressure guns are available Consult...

Page 487: ...inside fig 7 3 Inspect the butt weld in the rim flange area to make Snap into place using a pair of slip joint pliers certain there is no groove or high spot fig 8 with one jaw on rim and one jaw on b...

Page 488: ...TS HOOD ADJUSTMENT The alignment of the hood is controlled by the position of the hood hinges and the height of the two bumpers lo cated one at each side of the radiator support The ad justment at the...

Page 489: ...eet Metal Chevrolet 1 Fender 2 Hood Hinge 3 Hood 4 Cowl Vent Grille 5 Molding 6 Trim 7 Radiator Support 8 Shroud 9 Radiator 10 Hood Lock 11 Hood Catch 12 Battery Tray 13 Skirt 14 Dust Shield 15 Bracke...

Page 490: ...velle 1 Fender 2 Hood Hinge 3 Hood 4 Cowl Vent Grille 5 Trim 6 Molding 7 Brace 8 Filler Panel 9 Reinforcement 10 Radiator Support 11 Shroud 12 Radiator 13 Hood Lock 14 Seal 15 Tie Bar 16 Hood Catch 17...

Page 491: ...t move ment and remove support from front of vehicle Installation 1 Position the radiator support in vehicle aligning mounting screw and bolt holes with drift punch 2 install screws and bolts loosely...

Page 492: ...y j Remove battery tray from vehicle 5 On Chevrolet remove screws securing bj ace fig 1 to skirt and dash panel and remove brace Remove skirt attaching screws and remove skirt from vehicle 4 6 Install...

Page 493: ...e bolt from Tool J 9559 Open hood far enough to allow passage of tool between hood and fender and insert encls of tool between coils of spring until barrel of tool contacts outer diameter of spring 2...

Page 494: ...ET MODELS EXCEPT STATION WAGONS Removal and Installation Lift the skirt fig 15 retaining lever at the bottom inside skirt flange over the lip of the flange and pull it downward Pull the skirt downward...

Page 495: ...h a non petroleum base volatile cleaner and allow to dry Follow the steps below for easy application of the film 1 Cut the tape backing the entire width of the transfer at the approximate centerline o...

Page 496: ...ble down 5 Remove the backing from the other half of the trans fer Apply this half in the same manner working from the center to the end and from the middle to the upper and lower edges 6 Fold the tra...

Page 497: ...0 Fig 11 Removing Spring with J 9559 Fig 13 Hood Insulator and Molding Chevrolet Fig 14 Hood and Hood Ornament Chevelle Fig 12 Installing J 9559 in New Spring Fig 15 Removing Rear Wheel Cover CHEVROLE...

Page 498: ...Page Battery Tray 14 Radiator Support 14 Fender Assembly 14 Trim 15 Skirt 15 Hood Assembly 18 Catch Assembly and Lock 18 Trim 18 Front End Assembly 18 1 Fender 2 Hood Hinge 3 Hood 4 Trim 5 Molding Fi...

Page 499: ...fender skirt and provide a shimming surface for precise alignment of front end and body when assembled The one piece radiator support panel completes a box section when welded to the front crossmember...

Page 500: ...od Lock Catch and Support Chevy II HOOD BUMPERS Hood bumpers must be adjusted until hood and fender line up as shown in Figure 17 HOOD CATCH AND LOCK Fig 19 Hood lock plate mounting holes are slotted...

Page 501: ...lowing removal procedure in reverse order Refer to torque specifications at rear of manual for correct torque values 4 Aim headlamps as outlined in Section 12 FRONT FENDER ASSEMBLY Removal 1 Remove he...

Page 502: ...er panel extension 5 Remove suspension bumper support shock absorber front spring and stabilizer link as outlined in Section 3 6 If removing left skirt assembly remove steering gear mounting bolts pow...

Page 503: ...y Manual Pay particular attention to welds cage nuts weld nuts and skirt mounting surfaces Cage and weld nuts may be repaired by outright replacement the best method or by the installation of spiral t...

Page 504: ...Hood Molding Clip equipped and connect tie rod end to steering arm as outlined in Section 9 6 Install radiator support and fender assembly as out lined in this section Install grille Section 13 7 If...

Page 505: ...h screw driver When installing a new molding force clips onto mount ing studs as far as possible and then clench clips with long nosed pliers to eliminate gap between molding and hood as shown in Figu...

Page 506: ...tlined in Section 9 under Maintenance and Adjustments Steering Gear Ad justments Remove jack stands and jack Bleed brakes as outlined in Section 5 Perform body alignment as outlined in Fisher Body Ser...

Page 507: ...d closing the hood HOOD BUMPERS Adjust hood bumpers so that hood top surface is flush with fender and header panel top surfaces See Figure 34 for correct sheet metal adjustment dimensions HOOD CATCH A...

Page 508: ...06 TO 18 GAP OUTBOARD OF NORMAL DOOR AT FENDER CENTER PEAK UNE HOOD FENDER FLUSH 06 TO FENDER AT CORNER FLUSH TO 06 NORMAL DOOR SURFACE TO BE MEASURED 2 REAR WARD OF DOOR EDGE TO FENDER EDGE FENDER T...

Page 509: ...ary Installation Install fender anci skirt assembly following the removal procedure in reverse order Refer to torque specifi cations in rear of manual for correct torque values HOOD ASSEMBLY Procedure...

Page 510: ...CHASSIS SHEET METAL 11 23 SHIM VIEW A SHIM VIEW B Fig 36 Fender to Cowl and Rocker Panel Shimming Camaro CHEVROLET CHASSIS SERVICE MANUAL...

Page 511: ...CHASSIS SHEET METAL 11 24 Fig 37 Camaro Hood Insulator and Ornament CHEVROLET CHASSIS SERVICE MANUAL...

Page 512: ...TOOLS The only special tool required for 1967 chassis sheet metal servicing is the hood spring removal and instal lation ToolJ 9559 See Figure 38 Fig 38 Special Tools All Models Hood Spring Tool J 955...

Page 513: ...ps are not used The sec tion of the grille covering the headlamps folds back when lights are required the headlamps are stationary The covering is retracted by a small electric motor mounted to the he...

Page 514: ...nector and is not integral with the wiring harness 3 The generator warning light and field circuitry 16 gauge wire is protected by a fusible link 20 gauge orange wire used in the battery feed to volta...

Page 515: ...ehicle 1 Drive vehicle onto selected aiming area Bounce vehicle several times and allow to settle 2 Remove headlamp bezels 3 Mount the T 3 Aimers on either the No 1 or No 2 pair of headlamps so that t...

Page 516: ...IEW WINDOWS BUBBLE Fig 6 Removing Aimer from Headlamp Fog 7 Selecting Level Aiming Area 4 After botli bubbles are centered turn the car around end for end making sure the tires are in the spots made o...

Page 517: ...and Camaro Rally Sport models rotate the headlamp panel to the open position 2 Remove headlamp bezel retaining screws and remove bezel On Chevrolet Chevelle and Camaro models lift bezel to disengage...

Page 518: ...on lamp housing to grille opening and install retaining nuts 7 Connect ground wire to attaching point and install retaining nut 8 Connect wiring harness to lamp socket and check operation of lamp Rais...

Page 519: ...lamp assembly and remove lens unit 3 Replace bulb lens or housing as required and posi tion assembly to fender opening Make sure wiring Fig 11 Parking and Fender Lamps Chevrolet Fig 12 Parking Lamp In...

Page 520: ...pening in body fig 14 9 Loosen alien screw in spacer and disassemble parts from the panel outboard pivot shaft 10 Install washer retainer felt seal bearing and spacer in that order to panel outboard p...

Page 521: ...shaft Slide motor onto shaft until it seats against shaft shoulder then install retainer in groove on locating stud Install motor to support retaining screw making sure ground wire is installed betwe...

Page 522: ...vrolet Chevelle Station Wagon Camaro and Chevy II Fig 17 1 Disconnect bulb socket from rear of lamp unit NOTE On station wagons remove lens to gain access to lamp or screws securing lamp housing to bo...

Page 523: ...Inside Rear Compartment Remove Retaining Screws Outside Remove Housing and Disassemble Remove From Outside Retaining Nuts in Rear Compartment Remove From Inside Remove From Outside Retaining Bolts Und...

Page 524: ...panel to facilitate removal of the outboard lamp assemblies 2 Position lamp assembly in body panel recess so that studs are aligned with holes in panel 3 Position lamp assembly ground wire over stud t...

Page 525: ...ELECTRICAL BODY AND CHASSIS 12 13 VIEWB BACKING LAMP VIEW A LICENSE LAMP LICENSE Fig 1 9 Backing and License Lamps CHEVROLET CHASSIS SERVICE MANUAL...

Page 526: ...harness con nector inside trunk on some models 3 Force grommet and Wiring down through body open ing where applicable and remove assembly from vehicle 4 To install replacement unit insert grommet and...

Page 527: ...mounting hole and install ferrule jmt 8 Insert switch control knob and shaft assembly into switch until retainer engages shaft WIPER SWITCH REPLACEMENT Fig 26 1 Disconnect battery ground cable 2 Remov...

Page 528: ...Y SWITCH Fig 22 AutoTrans Seat Separator Wiring Chevelle TAIL PANEL Ll J TAIL LIGHTS g 9 TUtflll DOME LIGHT r I m LIGHTS F U S E HEADLIGHTS 9R j l PARKING LIGHTS RATTPRY Fig 23 Light Switch Terminal C...

Page 529: ...ACEMENT Column Shift Fig 31 1 Disconnect wiring harness connectors at switch ter minals 2 Remove switch retaining screws and switch from mast jacket 3 To install position shift lever in drive and loca...

Page 530: ...onnect wiring and check op eration of switch Install indicator lamps housing lens ash tray and trim plate assembly Corvette Fig 32 1 Disconnect shift control lever arm from the control rod 2 Remove th...

Page 531: ...disengage switch from brace 3 To install reverse removal procedure INSTRUMENT PANEL COMPARTMENT LAMP SWITCH REPLACEMENT 1 Disconnect battery ground cable 2 Reach into glove box depress bulb in end of...

Page 532: ...AND CHASSIS 12 20 Fig 32 Neutral Safety Switch Corvette Fig 33 Paricing Brake Alarip Switch Corvette CHEVROLET CAMARO CHEVELLE CHEVY E Rg 34 Parking Brake Alarm Switch Exc Corvette CHEVROLET CHASSIS...

Page 533: ...speedometer and clock a tachometer fuel oil pressure ammeter and engine temperature gauges which replace the standard fuel gauge and indi cator lights The brake warning indicator is relocated to the t...

Page 534: ...ews 10 Install speed warning device control attaching nut and knob if so equipped II Connect battery ground cable and check operation of cluster assembly Fig 36 Instrument Cluster Installation Chevrol...

Page 535: ...cation 1 Disconnect the speedometer cable from the speedom eter head Remove the old cable by pulling it out from speedometer end of conduit NOTE If old cable is broken it may be neces sary to remove l...

Page 536: ...nsole 3 Remove cluster lamps from cover circuit attaching screws and terminal nuts at circuit to gauge attach ing points 4 Move printed circuit away from gauge and remove screws retaining _ gauge or c...

Page 537: ...Panel Wiring 10 To Wiper Switch 11 To Light Switch Conn 12 To Gen and Fwd LP Harness Asm 13 To Light Switch 14 Courtesy Lamp 15 To Dome Lamp Conn 16 T o L H Door Jam Switch 17 Gen and Fwd Harness Conn...

Page 538: ...essure indicator lamp and includes a clock on deluxe models On super sport models am meter coolant temperature and oil pressure gauges re place the appropriate indicator lights Except for the speedome...

Page 539: ...ect wiring connectors and cluster lamps from rear of gauge assembly 4 Remove mounting plate retaining screws 3 and re move fuel gauge from rear of cluster housing 5 Remove terminal nuts 3 securing gau...

Page 540: ...trument Cluster Lamp 3 Bright Indicator 4 Gen indicator 5 Temp Indicator 9 6 O i l Indicator 10 7 L H Directional Indicator 11 8 Fuel Gauge Connector 12 Bart Gauge Connector Parking Brake Alarm Indica...

Page 541: ...mperature Switch Replacement 1 Disconnect wiring harness connector from sender unit terminal located in block above starter on L 6 engines and at left front of distributor on V 8 engines 2 Remove send...

Page 542: ...ctor 6 W S Wiper Switch Connector 7 Light Switch Connector 8 L H Door Jamb Switch 9 To Body Harness Connector 10 Parking Brake Alarm Switch Connector 11 Directional Signal Switch Connector 12 Backing...

Page 543: ...e pedal is applied if a mal function should occur in the brake system due to a loss of hydraulic pressure Servicing of the hydraulic pressure differential switch is covered in Section 5 of this manaul...

Page 544: ...ll eight screws retaining cluster to console 9 Install mast jack upper clamp assembly 10 Connect battery ground cable and check operation of instruments and gauges FUEL GAUGE REPLACEMENT 1 Disconnect...

Page 545: ...r Switch 4 To Directional Signal Flasher 5 6 7 a To Heater Resistor To Blower Motor Connector To Cigarette Lighter To Ignition Switch 9 10 11 12 To Wiper Switch To Light Switch To Fisher Body Connecto...

Page 546: ...ck above starter on L 6 engines and at left front of distributor on V 8 engines 2 Remove sender unit replace with new unit and check operation GENERATOR INDICATOR 1 Ignition on engine not running and...

Page 547: ...ult to determine which unit is at fault when the gauge fails to operate properly Cluster removal is necessary to re place the fuel gauge NOTE Be sure to check gas gauge fuse in fuse panel before attem...

Page 548: ...ced as a unit if found defective The brake warning light serves a dual purpose It functions as an indicator when the parking brake is ap plied and also if there is a malfunction loss of hydraulic pres...

Page 549: ...gauge to cover detach unit 6 To install reverse removal procedure SEAT SEPARATOR INSTRUMENT CONSOLE Fig 54 Fuel Ammeter Temperature Oil Pressure Gauges Low Fuel Warning Unit and Clock 1 Disconnect ba...

Page 550: ...ENERATOR INDICATOR 1 Ignition on engine not running and indicator light off Indicator bulb is burned out replace bulb Open circuit or loose connection in the indicator light circuit 2 Indicator light...

Page 551: ...rette Lighter 5 To Ignition Switch 6 To Instrument Cluster 7 To Wiper Switch 8 To Light Switch 9 To Directional Signal Switch 10 To Stop Lamp Switch 11 To Backing Lamp Switch 12 Fuse Panel 13 To Dimme...

Page 552: ...is that one type has can celling and detent springs which are serviceable other wise both units are not repairable and must be replaced as an assembly in service Due to the integral design relationshi...

Page 553: ...evy U and Camaro models equipped with auto matic transmission remove column mounted dial in dicator housing and lamp assembly if applicable 7 Remove mast jacket lower trim cover retaining screws and r...

Page 554: ...into the cover feeding the signal switch wires through the cover 17 Align signal switch and bearing housing holes with holes in the cover Install three mounting screws through the holes 18 Slide three...

Page 555: ...ng bolts 16 Insert switch wiring terminals in multiple connector Use old connector and wiring for color guide 17 Position switch and install three mounting screws with short screw in top position 18 B...

Page 556: ...elle Fig 61 1 Make certain motor is in park position remove wiper arm and blade assemblies from transmission shaft Gear Box Section 12 54 General Description 12 56 Depressed Park 2 Speed Wiper Corvett...

Page 557: ...emove plenum chamber side cover and loosen huts retaining drive rod ball stud to crank arm 4 Remove three motor retaining bolts and motor On Camaro models pull wiper motor assembly from Fig 63 Wiper M...

Page 558: ...wiper motor is in park position 2 Working under instrument panel remove special retainer clip securing transmission linkage to motor crank arm 3 Disconnect linkage electrical connectors and washer ho...

Page 559: ...AND PUCE IT IN GROOVE ASSHOWN Fig 68 Releasing Brush Spring Tension wedged off by using two screw drivers between cam and plate 3 Clamp crank arm in a vise and remove crank arm retaining nut CAUTION...

Page 560: ...washers to replace gear cpver and terminal board rivets ASSEMBLY Refer to Figure 65 for exploded view of motor and gear train Motor Reassemble motor using reverse of disassembly procedures NOTE Armatu...

Page 561: ...ing CAUTION It may be necessary to carefully pry bellows lip out of the valve body groove Bellows a To remove bellows first remove valve assembly b Manually operate pump clockwise to release pump from...

Page 562: ...to break any of the retainer tabs 6 Install U shaped brush retainer clip over brush holder that has brush lead attached to circuit breaker fig 78 7 Holding the opposite brush from that retained in St...

Page 563: ...ase and Field Assembly Removal 1 Remove brush plate and armature 2 The end case and field assembly is serviced as a DRIVE PLATE ASSEMBLY DRIVE PAWL IN PARK POSITION IN RELAY SWITCH SLOT RELAY SWITCH A...

Page 564: ...llow re assembly of the remaining brush in its brush holder then position the brush plate assembly on the mounting tabs in the position shown in Figure 78 NOTE Circuit breaker ground lead will not rea...

Page 565: ...N GEAR J ASSEMBLY IN V POSITION SHOWN F T DURING REASSEMBLY WM IN HOUSING fINNER SPACER J WASHER ft as possible the case and field assembly with the housing Maintaining the armature in its assembled p...

Page 566: ...h attaching screw fig 80 and carefully lift the relay switch assembly out of the gear box Unsolder leads from switch terminals as required Refer to Figure when resoldering leads To remove terminal boa...

Page 567: ...ear guide channel fig 88 4 Holding the gear manually rotate the drive plate until the drive and lock pawl guide pins snap into their respective pockets in the gear fig 88 5 Reinstall coil spring betwe...

Page 568: ...sembly lead wires 6 Remove glove box door and compartment Refer to Section 1 for removal procedure 7 Make sure wiper arms and wiper motor are both in the parked position then remove the wiper trans m...

Page 569: ...on a spring similar to that shown in Figure 95 and insert behind the brush leads as shown Fig 95 Retaining Armature Brushes 6 Pull the armature out of the case and remove the felt washer thrust plate...

Page 570: ...D FOLLOWER Reassembly 1 Assemble rubber thrust disc steel thrust plate and felt washer in order indicated fig 96 2 Be sure steel thrust ball is located in commutator end of armature shaft lubricate ar...

Page 571: ...7 Disconnect coil spring remove E ring and lift the latch and follower assembly off the pivot pin and relay armature 3 Remove the stop assembly retaining screw This will permit the stop assembly to be...

Page 572: ...ed from the wiper assembly as a unit therefore it is not necessary to remove the wiper assembly from the vehicle if only the washer pump and or valve assem bly requires service WASHER PUMP SECTION PUM...

Page 573: ...TRICAL BODY AND CHASSIS 12 61 R H FENDER LAMP 1 6600 R H PARK DIR S1G LAMP L H PARK DIR SIG LAMP L H FENDER LAMP 16600 Fig 104 Front Lighting Engine Compartment Chevrolet CHEVROLET CHASSIS SERVICE MAN...

Page 574: ...SM 12 BRN 20 Y 12 BRN 67 MOD ONLY 45 MOD ONLY 14 PPL DIRSIG FLASHER 20 BRN 20 LBL 20 P 16 BRN 20 LG 20 PPL 14 LBL 20 T 20 OR 20 DG 20 Y 20 LG 20DBL W 20 D G 1 6 BRN 20 D G 10 O R TAPE BACK 10 OR 10 OR...

Page 575: ...CLUSTER ILLUM ILLUM R H S GEN OILP ILLUM ILLUM 20 GY 20 GY 20DBI 20DBL W 18 W 16BRN CLOCK i T 0 ILLUM L Y 18 B 18 DBL 18 LBL HIGH BEAM 11 ILLUM FUEL GAGE 30 ILLUM I L L U M PARK BRAKE ALARM BRAKE WAR...

Page 576: ...LY 18 T f 18 W MODELS OHLY L H RR DRJAMBSW 16639 ONLY R H TAIL STOP DIRSIG LAMP OUTBOARD R H TAIL LAMP MID 16400 600 ONLY R H BACK UP LAMP MID ALL MOD EXC 16400 600 16400 600 BUMPER MOUNTED R H TAIL S...

Page 577: ...D R H TAIL LAMP MID 16400 600 ONLY R H BACK UP LAMP MID ALL MOD EXC 16400 600 16400 600 BUMPER MOUNTED R H TAIL STOP DIR SIG LAMP 16000 MOD ONLY INBOARD LICENSE LAMP L H TAIL STOP DIR SIG LAMP 16000 M...

Page 578: ...CAL BODY AND CHASSIS 12 66 R H PARK DIR SIG LP L H PARK DQU SIG LP GROUND TO FENDER REINF BRAKE FLUID i l l WARNING SW Fig 109 Front Lighting and Engine Compartment Chevelie CHEVROLET CHASSIS SERVICE...

Page 579: ...R 20 LBL 20 LBL 20 B 20 LG 20 PPL 16 LG 12 PPL W 12 PPL NEU SAF SW FLOOR SHIFT RPOM35 20 LG f 20 DG 18 DG 18 L G BACKUP LP SW FLOOR SHIFT 1 8 O R 20Y 12 PPL W 12 R 12 P _ 20 DG 14 BRN 12 BRN 24 BRN W...

Page 580: ...12 P 20 DG 14BRN 12 BRN 24 BRN W 14 OR 20 GY 12 PPL W 12 R 12 P 24 BRN W 14 OR BRK ALARM IND HI BEAM IND LP GEN IND LP TEMP IND LP INST CL LP OIL PRESS IND LP HORN BUTTON TO TRAFFIC HAZARD SW 20DBL IN...

Page 581: ...ONLY ALL EXC LIC LP 18 BRN GROMMET 18 BRN LICLP I FUEL MTR 8 I f I I FUEL MTR H 18 B L H BACKING LP 18 LG 20 LG 20 BRN GROMMET 18 B I t L H TAIL STOP DIR SIG LP I I I L H BACKING LP 20 LG El W 18 LG...

Page 582: ...ELECTRICAL BODY AND CHASSIS 12 70 20DBL 16BRN 20LBL 20B 12R Fig 113 Front Lighting Engine Compartment Chevy H CHEVROLET CHASSIS SERVICE MANUAL...

Page 583: ...14W FUSE PNL ASM 20LG 20P 12PPL 12PPL NEUSAF RPO M 35 11700 800 18DBL 12PPL 16BRN 12BRN 24BRN W NEUSAFSW RPO M 35 ALLEXC 11700 800 7 T RPO M 35 20LBL 20DBL 20PPL 14LBL 20PPL 14LBL 20LG 12R 20DG C Fig...

Page 584: ...W 20DBL 18LBL _ 12P 12R 20P 18DBL 18LBL 20DG 20T 20T 20PPL 14LBL 20LG 1 2 R 20DG 20Y 18LBL 140R 18Y 20OR I GLOVE COMPTLP SW ALL EXC 11100 300 nn 4 0 0 20GY 3 p HTRLP 20GY CLOCK LP CLOCK CONN 11700 800...

Page 585: ...OLET WRG FISHER BODY WRG mm mm mm CHEVROLET RPO WRG DOMELP FUEL MTR BRN R H BK UP LP I I GROM UC LP o ooeo STA WAG STAWAG SEDAN ONLY STA WAG ONLY g I I I L H BK UP LP 20LG 20BRN 20Y K L H TAIL STOP DI...

Page 586: ...P 18 LG 18 P DASH PANEL RESISTOR TEMP SENDER R H LIMIT SW L H LIMIT SW GY B 16 DBL BRK FLUID WARNING 16 W 20 OR 20 B BACK UP LMP SW 20 B 16 B W 18 T NEU SFT SW I RPO M35 4BRN W 16 B M18DG 4 OR DIR SI...

Page 587: ...TER RESISTOR 14 L B L 14 OR 14 Y 12PPL LG R H COURT LP 1 2 BRN cmcurr BREAKER R H DOOR JAMB SW 2 0 O R 18 LBL 20 Y 14PPL 20 W X 20DG 20 P 18 CfY DBL B 20 B 14 OR 14 LBL L H DOOR JAMB SW 20 P Fig 118 F...

Page 588: ...T HORN CONTACT 16B W 20 LG 18 P 12 R 18 GY DBL B 20 B 14 OR 14 LBL 16 B 20 W 12 R 18 LBL 14 LBL 20 PP 18 OR 20 BRN 16 DG IGNTTION SWITCH GROUND IGNITION LAMP INST LAMP RADIO CAPACITOR CONN T E M P GA...

Page 589: ...ARM SW 18 W 18 OR 18 T 18 BRN BODY CONNECTOR 18 LG 18 DG 18 Y 18 P 16 B R H TAIL STOP DIR SIG LAMP OUTBOARD R H TAIL STOP DIR sia LAMP ONBOARD R B BACK UP LAMP LICENSE LAMP L H BACK UP LAMP L H TAIL S...

Page 590: ...I 1 6 T 16LG 1 0 R JUNCTION BLOCK 20B DASH PNL T 12B 14R 6B 2...

Page 591: ...ELECTRICAL BODY AND CHASSIS 12 79 14LBL 20DBL 20DBL 20PPL 20LBL 20LBL 20B 12R Fig 122 Fuse Panel Camaro CHEVROLET a t SERVICE MANUAL...

Page 592: ...T 12PPL 20LBL 20 T 14 OR 16BRN 20DBL 20 W 18LBI 18DBL 20LG 20DG 20 DG 20BRN 20OR 20PPL 14LBL 14OR 48LBL 18B 18DBL R H DOOR JAMBSW INSTRUMENT CLUSTER ILLUM 8 BRAKE ALARM 33 39 R H SIGLAMP 15 GEN WARN L...

Page 593: ...HEVROLET RPO WRG 2ODG irnvi 20BRN V p 20LG R H TAIL STOP DIRSIG LAMP R H BACK UP LAMP II I BODY HARNESS 18BRN 18T 18T 18B LICENSE LAMP I I I II 20LG 20Y 20BRN L H BACK UP LAMP L H TAIL STOP DIRSIG LAM...

Page 594: ...ALL VEHICLES NOTE Reach upper two shroud bolts from top EXCEPT CORVETTE between hood and radiator support Reach lower 4 by reaching around front edge of open hood Removal 1 Drain radiator 4 Remove shr...

Page 595: ...e bar and re 9 move hood catch from vehicle Remove screws attaching headlamp bezels to grille reinforcements fenders and filler panel Remove bezels and headlamps from vehicle Remove screws and rivits...

Page 596: ...nts removed are undamaged they may be used for the new grille installation Where rivets were re moved make new attachments using screws and nuts patent clips or rivets Installation Install grille and...

Page 597: ...l and filler panel reinforcements to fenders fender braces and radiator support and remove filler panel 12 If necessary remove nuts attaching name plate to grille and replace name plate Repair If any...

Page 598: ...ation Where rivets were removed make new attachments using screws and nuts patent clips or rivets Installation Install grille and related components following the re moval procedure in reverse order R...

Page 599: ...move header panel Remove hardware attaching upper and lower grilles to vehicle and remove upper and lower grilles Remove screws attaching valance panel to fenders and fender extensions and retractable...

Page 600: ...RADIATOR AND GRILLE 13 7 Fig 6 Fender Trim Plate Attaching Hardware Fig 7 Grille Assembly Chevrolet Fig 8 Grille Assembly Chevelie CHEVROLET CHASSIS SERVICE MANUAL...

Page 601: ...RADIATOR AND GRILLE 13 8 Fig 9 Grille Assembly Chevy II Fig 11 Grille Assembly Comoro Fig 10 Grille Assembly Corvette CHEVROLET CHASSIS SERVICE MANUAL...

Page 602: ...wo holes are pierced in the center face bar for the parking lamps The bumper attaching brackets are lengthened to attach in common with new front bumper diagonal braces The rear bumper is a new three...

Page 603: ...3 back up lamp each bumper brace to retaining bumper 4 Remove bolts retaining each bumper bracket to bumper and separate sections of face bar at joints 5 The license plate door sedan models and bumper...

Page 604: ...rns align ing holes in brackets and braces with those in the frame 2 Loosely install bolts lock washers and nuts Note that eight sided adjustment washer fig 3 is placed in the tab of each mounting bra...

Page 605: ...and install parking lamps to face bar Install all bolts loosely do not tighten any bolts until all bolts have been installed Installation 1 Position assembled bumper on frame extensions aligning holes...

Page 606: ...from frame member and weld or braze new one in place GENERAL DESCRIPTION CORVETTE The front and rear Corvette bumpers are of the two piece wrap around type The front bumpers are con nected by a center...

Page 607: ...ical Removal 1 Remove bolt retaining bumper assembly to fender extreme outer end 2 Remove bolt retaining bumper to outer brace 3 Remove bolt retaining bumper to inner upper brace 4 Remove bolt retaini...

Page 608: ...ssembly 1 Remove bolts attaching two support brackets to bumper 2 Remove screw and nut securing license plate bracket to bumper Assembly Assemble the front bumper following the disassembly procedure i...

Page 609: ...s in bumper brackets with those in frame 2 Loosely install all bolts lock washers and nuts In sure bumper is in correct mounted position 3 Tighten all bolts securely and lower vehicle Fig 10 Front Bum...

Page 610: ...Service Operations 15 7 System Checks 15 10 REGULATOR TO INTAKE MANIFOLD HOSE SERVO All BLEED HOSE VACUUM RELEASE SWITCH HOSE THROTTLE CHAIN CABLE TO SPEEDOMETER ENGAGEMENT BUTTON RIC RELEASE SWITCH V...

Page 611: ...t to both the resistance and standard solenoid feed wires and the solenoid becomes de activated During vehicle operation the three switch positions have the following functions Released a System not e...

Page 612: ...center of the unit and the air bleed port is near the outer wall When vacuum is applied to the center port atmospheric pressure moves the diaphragm which pulls on the bead chain opening the carbureto...

Page 613: ...mechanism within the unit the speedometer cable from the transmission drives the Regulator which drives a second cable at a one to one ratio to the speedometer The Regulator is electrically engaged an...

Page 614: ...on the orifice tube thereby covering and uncovering air ports in the wall of the tube the tube inner end is plugged whenever car speed changes from the speed at which the solenoid was energized The di...

Page 615: ...ns to ascend a hill car speed drops slightly very slightly and the magnetic force on the driven disk of the speed sensor is decreased The disk rotates slightly as would a speedometer shaft because of...

Page 616: ...ent Switch the unit pulls in and holds in in the normal manner The air bleed valve is clutched to the rubber drum at the car speed during switch release Vacuum is again applied to the Servo and thrott...

Page 617: ...BLUE REGULATOR SOLENOID COIL 5 a RESISTANCE 9 BLACK BLUE REGULATOR Fig 10 Wiring Diagram Replacement 1 Insert the switch into the turn signal knob push the retaining ring firmly against the switch an...

Page 618: ...plug push button control connector brown blue black at electrical wiring harness con nector and perform the following tests See Fig ure 10 Test 1 Connect ohmmeter between terminal 1 brown wire and ter...

Page 619: ...changed at Servo Defective Regulator Defective Engagement Switch or Wiring Internally Misadjusted Regulator Correction Check connections adjust or replace switch Refer to Electrical Check Out Replace...

Page 620: ...t control valve The COMPRESSOR is a two stage vacuum actuated type requiring no lubrication Vacuum supply is taken from engine carburetor base High pressure air is supplied to the reservoir tank by th...

Page 621: ...an internal lever to open the intake valve when this valve is open high pressure air is admitted to the Superlift shocks As the car raises to level the intake valve shuts off When load is removed fro...

Page 622: ...8 tubing g Two male connectors which have a 1 8 male taper pipe thread on one end and a 3 8 24 straight thread male fitting on the other end 2 Assembly a Connect Fill Valve J 21999 female end at male...

Page 623: ...cord rear trim height of empty car rear bumper to ground 2 Add weight equivalent to two passenger load to rear of car Car should begin to level in 4 18 seconds 3 Remove weight After 4 18 seconds car s...

Page 624: ...allation 1 Disconnect air lines manifold and air cleaner at compressor end 2 Disconnect pressure line at compressor head 3 From wheel side of fender skirt remove two screws from bracket on compressor...

Page 625: ...alve 53 Bushing Distributor Valve 54 Washer 160 163 I D 55 Arm Assembly Distributor 56 Screw 57 Spring Valve Tension 58 Bushing Distributor Valve Stop 59 Bussing Arm Assembly Stop 60 Arm Actuating 61...

Page 626: ...If distributor mechanism failed to function properly or one or more parts were found defective use new parts in distributor valve and arm package during remaining build up 2 Install washer on intake...

Page 627: ...pressor retaining through bolts that secure second stage housing to first stage housing Housings will align one way only Nuts are posi tioned in counterbores in second stage housing Tighten to 28 in l...

Page 628: ...mp In Line 30 amp 30 amp 20 amp 20 amp SECTION 3 WHEEL ALIGNMENT SPECIFICATIONS Vehicle dt Curb Weight Caster Camber Steering Axis Inclination tToe In Total Wheel Bearing Adjustment Preload End Moveme...

Page 629: ...orber Upper Shaft Nut Lower Attachment Bracket to Spring Tower Stabilizer Bar Frame Bracket Bolts Link Nuts Strut Rod Rod to Arm Nut Adjustment Nut Front Spring Spring Seat to Control Arm Nuts Lower C...

Page 630: ...earing Caps 55 Filler Plug 20 Differential Pinion Lock 20 Type Heavy Duty Axle Light Duty Axle Bolt Torque ft lbs Spring Retainer Control Arm Upper Front Bracket Upper Bushings Lower Bushings Shock Ab...

Page 631: ...5 50 Install nut to expose hole Corvette then insert cotter pin only Neg 1 2 1 2 1 32 to 3 32 Station Wagon All 4 Link System Plus additional torque necessary to line up cotter pin hole Camber must no...

Page 632: ...ions Brake Hose to Brake Assembly Connection Parking Brake Equalizer Check Nut Hydraulic Brake Pipe Connections Rear Brake Hose to Rear Brake Line T Connection Caliper Half Retaining Bolts Caliper to...

Page 633: ...0 275 4800 355 3200 300 5000 360 3400 325 5600 355 3600 350 5800 360 3600 350 295 4800 380 3200 4 3 25 75 1 10 0 1 11 0 1 3 48 396 325 4800 410 3200 350 5200 415 3400 4 3 32 427 385 5200 460 3400 390...

Page 634: ...0 425 435 9270 9273 00015 00025 00045 00055 0015 0025 9895 9898 0O025 00035 00030 00040 001 Max 0008 0016 Interference All 2 298S 2 2993 1 2 2984 2 2993 2 3 4 2 2983 2 2993 5 2 2978 2 2988 1 2 3 4 2 4...

Page 635: ...390 400 425 435 1 75 1 Hydraulic 1 50 1 One One Mechanical 1 70 1 Turn Down From Zero Lash Turn Down From Zero Lash 022 024 024 028 4 5 46 002 Max 1 32 1 16 1 16 3 32 0015 0032 0010 0027 0010 0027 001...

Page 636: ...6 Accelerator Pump 015 Idle Vent Mechanical 065 065 Fast Idle 025 035 025 Final 2200 RPM 2000 RPM 2200 RPM 2000 RPM 2200 RPM Choke Vacuum Break 220 240 220 240 240f 190 350 190 175 190 175 175 175f 25...

Page 637: ...e Idle Vent 050 3 8 Fast Idle Mechanical 3 Turns After Contact Running 2200 RPM 2000 RPM 2200 RPM 2200 RPM Carburetor Choke Rod 90 100 90 100 90 100 060 100 Choke Vacuum Break 140 160 140 160 140 160...

Page 638: ......

Page 639: ...rand 5 lbs Used 140 5 lbs New Using Strand 5 lbs Used 75 5 lbs New Using Strand r Hydraulic One Turn Down From Zero Lash Hydraulic One Turn Down From Zero Lash 500 X 700 600 3 to 700 500 4 1 2 500 600...

Page 640: ...ver Construction GENERATOR Generator Model Application Field Amp Draw Hot Output Amps Cold Output Volts 1100695 Chevy n Exc V 8 Sta Wgn or AC 2 2 2 6 32 14 1100693 Chevy n w V 8 Camaro CheveUe Chevrol...

Page 641: ...d Volts Amperes RPM Resistance Test Armature Locked Volts Amperes 1107399 153L 4 194L 6 230L 6 w Mariual Trans 230L 6 w Auto Trans 250L 6 All Trans 35 10 6 49 87 6200 10700 4 2 290 425 1107400 153L 4...

Page 642: ...4100 0 900 10 1500 15 2000 28 4200 0 900 9 1200 15 1500 30 5100 0 900 19 1200 25 1500 40 5100 0u 900 9 1200 15 1500 30 5100 0 900 9 1200 15 1500 30 5100 0b 900 9 1300 15 1700 26 4700 0B 900 8 5 1250...

Page 643: ...Primary Resistance Ohms Secondary Resistance Ohms Ignition Resistor Type Ohms L 4 L 6 1 45 1 63 5600 6900 1 8 V 8 Non Transistor 1 24 1 46 6500 9500 Fixed In Wiring Harness 1 8 V 8 Transistor 38 51 82...

Page 644: ...haft Nut 25 ft lbsi Lubrication Filler and Drain Plugs 20 ft lbs Transmission Case to Clutch Housing Bolts 55 ft lbs Crossmember to Frame Nuts 25 ft lbs Crossmember to Mount Bolts 40 ft lbs FOUR SPEED...

Page 645: ...r Pan to Transmission Case 7 1 2 ft lbs Oil Cooler Pipe Connectors to Transmission Case or Radiator 10 ft lbs Oil Cooler Pipe to Connectors 10 ft lbs Vacuum Modulator to Transmission Case 15 ft lbs Oi...

Page 646: ...17 5 1 21 3 1 17 5 1 20 4 1 870 1000 Recirculating Ball 900 1000 Integ Recirc Ball 17 5 1 17 5 1 870 1000 Recirculating Ball 17 6 1 Only ADJUSTMENT SPECIFICATIONS STANDARD STEERING Adjustment Worm Bea...

Page 647: ...Pump Pulley Power Steering Mounting Bolt Power Steering Mounting Nut Power Cylinder to Relay Rod Nut Power Cylinder to Frame Bracket Control Valve to Pitman Arm Control Valve Clamp Bolt Steering Shaf...

Page 648: ...ment would require pressures greater than the TpaxiTP Tns stated above 3 Cool tire inflation pressure after vehicle has been inoperative for three 3 hours or more or driven less than one 1 mile Hot ti...

Page 649: ...ion over 75 MPH increase tire inflation pressures four 4 pounds per square inch over the recommended pressures up to a maximum of 32 pounds per square inch cool for 4 ply rating tires or 40 pounds per...

Page 650: ...5 When towing trailers the allowable passenger and cargo load must be reduced by an amount equal to the trailer tongue load on the trailer hitch CORVETTE Tire Usage and Recommended Tire Inflation Pre...

Page 651: ...sengers 750 lbs load Front 24 24 Rear 24 24 1 to 5 passengers 750 lbs load Front 22 22 Rear 26 26 1 to 5 passengers 750 lbs load Front 22 Rear 26 1 Tire inflation pressures may increase as much as six...

Page 652: ...et Camaro Chevelle and Chevy n Hi Beam Indicator Chevrolet Camaro Chevelle and Chevy II Corvette Directional Indicator Chevrolet Camaro Chevelle Chevy II Corvette Cigarette Lighter Lamp Corvette Ignit...

Page 653: ...til the cause is found and eliminated louses located in the Fuse Panel under the instrument panel are Wiper Chevrolet Chevelle and F Car 3AF AGC 20 Amp Back up Lamp and Gauges 3AG AGC 10 Amp Heater Ai...

Page 654: ...d Park Chevrolet Corvette Two Speed Operating Voltage 12 VDC Gear Ratio 3 36 1 Crank Arm Rotation Looking at Crank Arm Clockwise Crank Arm Speed No Load Lo 34 RPH min Hi 6 5 RPM min Current Draw amper...

Page 655: ...ossmember Nuts Front Bumper Bracket to Frame Nuts Front Outer Brace Center Brace to Frame Bolts Gas Tank Filler Door to Rear Bumper Nuts Rear Bumper to Frame Crossmember Nuts Rear Bumper to Bumper Bra...

Page 656: ...acer to Bumper Nuts Rear License Plate Bezel to Body Screws Chevrolet 50 lb ft 25 lb ft Chevelle 30 lb ft 45 lb ft for station wagon El Camino 53 lb ft 53 lb ft Chevy H 28 lb ft 28 lb ft Corvette 30 l...

Page 657: ...203125 21875 234375 25 265625 28125 296875 3125 328125 34375 359375 375 390625 40625 421875 4375 453125 46875 484375 5 33y 4 3 u U4 _ 4 S 4 2 2 S HA b A 515625 53125 546875 5625 578125 59375 609375 6...

Page 658: ...1695 0 1660 0 1610 0 1590 0 1570 0 1540 0 1520 0 1495 0 1470 0 1440 SIZES Wire Gage Sizes 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Drill Diam Inches 0 1405 0 13...

Page 659: ...1838 1685 1532 1379 1225 1072 0919 0766 0689 0613 0551 0490 0429 0368 0337 0306 0276 0245 0214 0184 0169 0153 0138 0123 0107 0100 0092 0084 0077 0069 0065 0061 0057 0054 0052 0050 0048 0046 AMERICAN...

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Chevrolet 1962 Chevy II, Service Manual

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